Monolithic precursor test coupons for testing material properties of metal-injection-molded components and methods and apparatuses for making such coupons

ABSTRACT

A flash-removal tool comprises a tool body, extending along a longitudinal tool axis, and a tooth, projecting from the tool body in a first direction. The flash-removal tool further comprises an engagement surface, perpendicular to the longitudinal tool axis and located a preselected distance away from the tooth along the longitudinal tool axis. The tooth comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction. The first direction and the second direction are orthogonal to each other and define a plane, perpendicular to the longitudinal tool axis.

TECHNICAL FIELD

The present disclosure relates to a monolithic precursor test coupon fortesting material properties of metal-injection-molded components.

BACKGROUND

Components of various structures are manufactured using metal injectionmolding (MIM) techniques. MIM processes employ granular feedstock thatincludes powdered metal. Such feedstock is injected into a mold to forma green part, which is substantially geometrically similar to the finalcomponent, although the green part may be oversized relative to thefinal component to account for shrinkage during the subsequent sinteringstep. Next, the green part is subjected to de-binding, for example in athermal or solvent-based process, to remove the binder and form a brownpart. The brown part is then sintered at high temperatures to form thefinal, substantially metallic component.

It is often necessary and/or desirable to quantify certain materialproperties of MIM-manufactured components by testing coupons, formed inthe same way and from the same materials as the components of interest.Such test coupons typically have a reduced central cross-sectional areaand are sometimes referred to as “dog bone” coupons. When injectingfeedstock through the mold during the MIM process to produce a testcoupon, the reduced central cross-sectional area acts as a restrictionthat inhibits proper flow of the feedstock through the reduced-areasection of the coupon. If feedstock injection pressure is increased toovercome the restriction, in some cases feedstock material is pushedthrough the restriction too quickly, shearing the binder away from thefeedstock. If the binder is not uniformly distributed throughout thegreen test coupon after the injection-molding process is completed, thecoupon may become warped during sintering. On the other hand, if thefeedstock is pushed through the restriction too slowly, the bindercross-links before injection is completed, and the feedstock materialtends to solidify, preventing further injection.

Due to the fact that green parts are relatively brittle, a long, narrowgreen part having a reduced-area central section may not survive typicalmold-ejection techniques without damage. Mold-release agents aretypically not used in MIM processes because of potential feedstockcontamination problems. Accordingly, an increased number of ejector pinsmay be incorporated into the mold to provide better distribution of theejection force, experienced by the green test coupon during themold-release step, in an attempt to reduce the possibility of damagingthe coupon as it is released from the mold. However, since the long,narrow shape and the reduced central cross-sectional area of the couponrequire elevated injection pressures during the MIM processes, bindermay flow into spaces between the ejector pins and the mold, causing theejector pins to stick to the mold and become incapable of ejecting thecoupon from the mold. Moreover, a long, narrow green part having areduced-area central section, such as a green test coupon formed by anMIM process, as described above, may warp at the elevated temperatures,associated with sintering.

A green test coupon formed in an MIM process may also have undesirable“flash,” i.e., ridges of excess material, formed by feedstock, seepinginto the mold parting lines during the MIM process. Removal of flashfrom a long, narrow green part using conventional manual techniquesintroduces the risk of damaging the coupon.

SUMMARY

Accordingly, apparatuses and methods, intended to address at least theabove-identified concerns, would find utility.

The following is a non-exhaustive list of examples, which may or may notbe claimed, of the subject matter, disclosed herein.

Disclosed herein is a monolithic precursor test coupon that comprises afirst grip portion, a second grip portion, and an intermediate portion,interconnecting the first grip portion and the second grip portion. Themonolithic precursor test coupon also comprises runners, directlyinterconnecting the first grip portion and the second grip portion andnot directly connected to the intermediate portion. The first gripportion, the second grip portion, the intermediate portion and therunners are composed of a substance that comprises metal powder and isin a green state.

The runners provide the monolithic precursor test coupon with increasedstability and inhibit breakage or warping of the first grip portion, thesecond grip portion, and the intermediate portion during and after aprocess of forming the monolithic precursor test coupon, such as duringone or more of: removal, in the green state, from a mold such as a metalinjection molding (MIM) apparatus; de-binding; and sintering. Inaddition, because the runners interconnect the first grip portion andthe second grip portion, and thus are not directly attached to theintermediate portion, removal of the runners during a process of forminga test coupon from the monolithic precursor test coupon poses adecreased risk of damage to the intermediate portion, facilitatingaccuracy in subsequent material property testing using the test couponformed from the monolithic precursor test coupon.

Also disclosed herein is a metal-injection-molding (MIM) apparatus formaking a monolithic precursor test coupon. The MIM apparatus comprises amold, defining a mold cavity. The mold cavity comprises afirst-grip-portion cavity and a second-grip-portion cavity. The moldcavity also comprises an intermediate-portion cavity, interconnectingthe first-grip-portion cavity and the second-grip-portion cavity. Themold cavity further comprises runner cavities, directly interconnectingthe first-grip-portion cavity and the second-grip-portion cavity and notdirectly connected to the intermediate-portion cavity. The MIM apparatusadditionally comprises an injector that is operable to inject feedstockmaterial, comprising a metal powder, into the mold cavity to form themonolithic precursor test coupon.

The MIM apparatus enables homogeneous distribution of the feedstockmaterial within the first-grip-portion cavity, the intermediate-portioncavity, and the second-grip-portion cavity to facilitate formation ofthe monolithic precursor test coupon in the mold with reduced oreliminated voids, and further with reduced or eliminated shearing of abinder that is included in the feedstock material along with the metalpowder. More specifically, the runner cavities enable a portion of thefeedstock material to bypass a flow restriction caused by theintermediate-portion cavity and provide back-fill of downstream portionsof the monolithic precursor test coupon. The bypass flow area providedby the runner cavities thus enables formation of the monolithicprecursor test coupon having a proper distribution and integrity of thefeedstock material at an injection rate that avoids problems of bindershearing or premature binder cross-linking.

Additionally disclosed herein is a flash-removal tool that comprises atool body, extending along a longitudinal tool axis. The flash-removaltool also comprises a tooth, projecting from the tool body in a firstdirection. The flash-removal tool further comprises an engagementsurface, located a preselected distance away from the tooth along thelongitudinal tool axis and perpendicular to the longitudinal tool axis.The tooth comprises a shearing surface, facing in the first directionand located an offset distance away from the longitudinal tool axis in asecond direction. The first direction and the second direction areorthogonal to each other and define a plane, perpendicular to thelongitudinal tool axis.

The engagement surface being spaced apart from the tooth by thepreselected distance enables the tooth to align longitudinally with thegauge portion when the engagement surface engages the monolithicprecursor test coupon. Moreover, the tooth projecting from the tool bodyin the first direction and having the shearing surface spaced at theoffset in the second direction enables the tooth to slide betweenrunners of the monolithic precursor test coupon such that the shearingsurface aligns precisely with the flash on a gauge portion of themonolithic precursor test coupon. Thus, the flash-removal toolfacilitates removal of the flash from the gauge portion, while therunners are still attached to the monolithic precursor test coupon,without requiring complex alignment procedures or adjustments.

Further disclosed herein is a method of making a test coupon using amold. The mold defines a mold cavity that comprises a first-grip-portioncavity, a second-grip-portion cavity, and an intermediate-portioncavity, interconnecting the first-grip-portion cavity and thesecond-grip-portion cavity. The mold cavity further comprises runnercavities, directly interconnecting the first-grip-portion cavity and thesecond-grip-portion cavity and not directly connected to theintermediate-portion cavity. The method comprises injecting feedstockmaterial, comprising a metal powder, into the mold cavity to form themonolithic precursor test coupon in the mold cavity. The monolithicprecursor test coupon comprises a first grip portion, having a shapecomplementary to that of the first-grip-portion cavity, and the secondgrip portion, having a shape complementary to that of thesecond-grip-portion cavity. The monolithic precursor test coupon alsocomprises an intermediate portion, having a shape, complementary to thatof the intermediate-portion cavity, and runners, each having a shapecomplementary to that of a corresponding one of the runner cavities. Themethod also comprises removing the runners from the monolithic precursortest coupon.

The method enables homogeneous distribution of the feedstock materialwithin the first-grip-portion cavity, the intermediate-portion cavity,and the second-grip-portion cavity to facilitate formation of themonolithic precursor test coupon in the mold with reduced or eliminatedvoids, and further with reduced or eliminated shearing of a binder thatis included in the feedstock material along with the metal powder. Morespecifically, the runner cavities enable a portion of the feedstockmaterial to bypass a flow restriction caused by the intermediate-portioncavity and provide back-fill of downstream portions of the monolithicprecursor test coupon. The bypass flow area provided by the runnercavities thus enables the formation of the monolithic precursor testcoupon having a proper distribution and integrity of the feedstockmaterial at an injection rate that avoids problems of binder shearing orpremature binder cross-linking. Removal of the runners from themonolithic precursor test coupon leaves the first grip portion, theintermediate portion, and the second grip portion of a test coupon formaterial property testing, such as in a tensile-test machine.

Also disclosed herein is a method of removing flash from a gauge portionof a monolithic precursor test coupon using a flash-removal tool. Theflash-removal tool comprises a tool body, extending along a longitudinaltool axis. The flash-removal tool also comprises a tooth and anengagement surface, spaced apart from the tooth along the longitudinaltool axis. The tooth projects from the tool body in a first directionand comprises a shearing surface, facing in the first direction andlocated an offset distance away from the longitudinal tool axis in asecond direction. The first direction and the second direction areorthogonal to each other and define a plane, perpendicular to thelongitudinal tool axis. The method comprises coupling the engagementsurface of the flash-removal tool against a first precursor-coupon endof the monolithic precursor test coupon. The method also comprisesorienting the longitudinal tool axis parallel to a longitudinal symmetryaxis of the monolithic precursor test coupon, wherein the shearingsurface registers longitudinally.

The tooth projecting from the tool body in the first direction andhaving the shearing surface spaced at the offset in the seconddirection, such that the shearing surface registers longitudinally withthe flash when the engagement surface of the flash-removal tool couplesagainst the first precursor-coupon end and the longitudinal tool axis isoriented parallel to the longitudinal symmetry axis of the monolithicprecursor test coupon, facilitates removal of the flash from the gaugeportion at an increased speed, without requiring complex alignmentprocedures or adjustments.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described one or more examples of the present disclosure ingeneral terms, reference will now be made to the accompanying drawings,which are not necessarily drawn to scale, and wherein like referencecharacters designate the same or similar parts throughout the severalviews, and wherein:

FIG. 1A is a block diagram of a monolithic precursor test coupon,according to one or more examples of the present disclosure;

FIG. 1B is a block diagram of a metal injection molding apparatus,according to one or more examples of the present disclosure;

FIG. 1C is a block diagram of a flash removal tool, according to one ormore examples of the present disclosure;

FIG. 2A is a schematic, perspective view of the monolithic precursortest coupon of FIG. 1A, having three runners, according to one or moreexamples of the present disclosure;

FIG. 2B is a schematic, perspective view of the monolithic precursortest coupon of FIG. 1A, having two runners, according to one or moreexamples of the present disclosure;

FIG. 2C is a schematic, perspective view of the monolithic precursortest coupon of FIG. 1A, having four runners, according to one or moreexamples of the present disclosure;

FIG. 3A is a schematic, elevation view of the monolithic precursor testcoupon of FIG. 1A, having respective curvatures contiguous withrespective grip portions, according to one or more examples of thepresent disclosure;

FIG. 3B is a schematic, elevation view of the monolithic precursor testcoupon of FIG. 1A, having a continuous curvature between respective gripportions, according to one or more examples of the present disclosure;

FIG. 4 is a set of schematic, elevation views of respective intermediateportions of the monolithic precursor test coupon of FIG. 1A, havingnotches, according to one or more examples of the present disclosure;

FIG. 5 is a schematic, elevation view of the monolithic precursor testcoupon of FIG. 1A, according to one or more examples of the presentdisclosure;

FIG. 6 is a schematic, sectional view of a portion of the monolithicprecursor test coupon of FIG. 5, according to one or more examples ofthe present disclosure;

FIG. 7 is a schematic, elevation, partial cut-away view of the metalinjection molding apparatus of FIG. 1B, according to one or moreexamples of the present disclosure;

FIG. 8A is a schematic, perspective view of the metal injection moldingapparatus of FIG. 1B, having three runner cavities, according to one ormore examples of the present disclosure;

FIG. 8B is a schematic, perspective, exploded view of the metalinjection molding apparatus of FIG. 1B, having three runner cavities,according to one or more examples of the present disclosure;

FIG. 8C is a schematic, perspective view of a portion of the metalinjection molding apparatus of FIG. 1B, including an ejector pin,according to one or more examples of the present disclosure;

FIG. 8D is a schematic, elevation, sectional view of a portion of themetal injection molding apparatus of FIG. 1B, including an ejector pin,according to one or more examples of the present disclosure;

FIG. 8E is a schematic, perspective view of the metal injection moldingapparatus of FIG. 1B, having four runner cavities, according to one ormore examples of the present disclosure;

FIG. 8F is a schematic, perspective view of the metal injection moldingapparatus of FIG. 1B, having two runner cavities, according to one ormore examples of the present disclosure;

FIG. 9 is a schematic, perspective, view of a test coupon formed fromthe monolithic precursor test coupon of FIG. 1A, according to one ormore examples of the present disclosure;

FIG. 10A is a schematic, perspective view of the flash-removal tool ofFIG. 1C, extending longitudinally on opposite sides of a tooth,according to one or more examples of the present disclosure;

FIG. 10B is a schematic, perspective view of the flash-removal tool ofFIG. 1C, extending longitudinally on one side of a tooth, according toone or more examples of the present disclosure;

FIG. 10C is a schematic, perspective view of the flash-removal tool ofFIG. 1C, being applied to the monolithic precursor test coupon of FIG.1A shown in partial cutaway view, according to one or more examples ofthe present disclosure;

FIG. 10D is a schematic, perspective view of the flash-removal tool ofFIG. 1C, applied to the monolithic precursor test coupon of FIG. 1A,according to one or more examples of the present disclosure;

FIG. 10E is a schematic, elevation, sectional view of the flash-removaltool of FIG. 1C applied to the monolithic precursor test coupon of FIG.1A, according to one or more examples of the present disclosure;

FIGS. 11A, 11B, and 11C, collectively, are a block diagram of a method,according to one or more examples of the present disclosure, of making atest coupon utilizing the apparatus of FIG. 1B, according to one or moreexamples of the present disclosure;

FIGS. 12A, 12B, 12C, and 12D, collectively, are a block diagram of amethod, according to one or more examples of the present disclosure, ofremoving flash from a gauge portion of a monolithic precursor testcoupon utilizing the apparatus of FIG. 1C, according to one or moreexamples of the present disclosure;

FIG. 13 is a block diagram of aircraft production and servicemethodology; and

FIG. 14 is a schematic illustration of an aircraft.

DETAILED DESCRIPTION

In FIGS. 1A, 1B, and 1C, referred to above, solid lines, if any,connecting various elements and/or components may represent mechanical,electrical, fluid, optical, electromagnetic and other couplings and/orcombinations thereof. As used herein, “coupled” means associateddirectly as well as indirectly. For example, a member A may be directlyassociated with a member B, or may be indirectly associated therewith,e.g., via another member C. It will be understood that not allrelationships among the various disclosed elements are necessarilyrepresented. Accordingly, couplings other than those depicted in theblock diagrams may also exist. Dashed lines, if any, connecting blocksdesignating the various elements and/or components represent couplingssimilar in function and purpose to those represented by solid lines;however, couplings represented by the dashed lines may either beselectively provided or may relate to alternative examples of thepresent disclosure. Likewise, elements and/or components, if any,represented with dashed lines, indicate alternative examples of thepresent disclosure. One or more elements shown in solid and/or dashedlines may be omitted from a particular example without departing fromthe scope of the present disclosure. Environmental elements, if any, arerepresented with dotted lines. Virtual (imaginary) elements may also beshown for clarity. Those skilled in the art will appreciate that some ofthe features illustrated in FIGS. 1A, 1B, and 1C may be combined invarious ways without the need to include other features described inFIGS. 1A, 1B, and 1C, other drawing figures, and/or the accompanyingdisclosure, even though such combination or combinations are notexplicitly illustrated herein. Similarly, additional features notlimited to the examples presented, may be combined with some or all ofthe features shown and described herein.

In FIGS. 11A, 11B, 11C, 12A, 12B, 12C and 12D, referred to above, theblocks may represent operations and/or portions thereof and linesconnecting the various blocks do not imply any particular order ordependency of the operations or portions thereof. Blocks represented bydashed lines indicate alternative operations and/or portions thereof.Dashed lines, if any, connecting the various blocks representalternative dependencies of the operations or portions thereof. It willbe understood that not all dependencies among the various disclosedoperations are necessarily represented. FIGS. 11A, 11B, 11C, 12A, 12B,12C and 12D and the accompanying disclosure describing the operations ofthe method(s) set forth herein should not be interpreted as necessarilydetermining a sequence in which the operations are to be performed.Rather, although one illustrative order is indicated, it is to beunderstood that the sequence of the operations may be modified whenappropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, those skilled in theart will appreciate that not all operations described need be performed.

In the following description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts will bedescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

Reference herein to “one or more examples” means that one or morefeature, structure, or characteristic described in connection with theexample is included in at least one implementation. The phrase “one ormore examples” in various places in the specification may or may not bereferring to the same example.

As used herein, a system, apparatus, structure, article, element,component, or hardware “configured to” perform a specified function isindeed capable of performing the specified function without anyalteration, rather than merely having potential to perform the specifiedfunction after further modification. In other words, the system,apparatus, structure, article, element, component, or hardware“configured to” perform a specified function is specifically selected,created, implemented, utilized, programmed, and/or designed for thepurpose of performing the specified function. As used herein,“configured to” denotes existing characteristics of a system, apparatus,structure, article, element, component, or hardware which enable thesystem, apparatus, structure, article, element, component, or hardwareto perform the specified function without further modification. Forpurposes of this disclosure, a system, apparatus, structure, article,element, component, or hardware described as being “configured to”perform a particular function may additionally or alternatively bedescribed as being “adapted to” and/or as being “operative to” performthat function.

Illustrative, non-exhaustive examples, which may or may not be claimed,of the subject matter according the present disclosure are providedbelow.

Referring generally to FIG. 1A and 1B, and particularly to, e.g., FIGS.2A, 2B, and 2C, monolithic precursor test coupon 100 is disclosed.Monolithic precursor test coupon 100 comprises first grip portion 110,second grip portion 112, and intermediate portion 114, interconnectingfirst grip portion 110 and second grip portion 112. Monolithic precursortest coupon 100 also comprises runners 130, directly interconnectingfirst grip portion 110 and second grip portion 112 and not directlyconnected to intermediate portion 114. First grip portion 110, secondgrip portion 112, intermediate portion 114 and runners 130 are composedof substance 150 that comprises metal powder 748 and is in a greenstate. The preceding subject matter of this paragraph characterizesexample 1 of the present disclosure.

Runners 130 provide monolithic precursor test coupon 100 with increasedstability and inhibit breakage or warping of first grip portion 110,second grip portion 112, and intermediate portion 114 during and after aprocess of forming monolithic precursor test coupon 100, such as duringone or more of: removal, in the green state, from a mold such as metalinjection molding (MIM) apparatus 700 (shown in FIG. 8A); de-binding;and sintering. In addition, because runners 130 interconnect first gripportion 110 and second grip portion 112, and thus are not directlyattached to intermediate portion 114, removal of runners 130 during aprocess of forming test coupon 900 (shown in FIG. 9) from monolithicprecursor test coupon 100 poses a decreased risk of damage tointermediate portion 114, facilitating accuracy in subsequent materialproperty testing using test coupon 900 formed from monolithic precursortest coupon 100.

Referring generally to FIG. 1A and particularly to, e.g., FIGS. 2A, 2B,and 2C, first grip portion 110, intermediate portion 114, and secondgrip portion 112 extend in series from first precursor-coupon end 102 tosecond precursor-coupon end 104 along longitudinal symmetry axis 106 andtogether define precursor-coupon body 108. The preceding subject matterof this paragraph characterizes example 2 of the present disclosure,wherein example 2 also includes the subject matter according to example1, above.

First grip portion 110, intermediate portion 114, and second gripportion 112 extending in series from first precursor-coupon end 102 tosecond precursor-coupon end 104 along longitudinal symmetry axis 106enable test coupon 900 (shown in FIG. 9) to be formed in near net shapefrom monolithic precursor test coupon 100 by removing runners 130.

Referring generally to FIG. 1A and particularly to, e.g., FIGS. 2A, 2B,and 2C, first grip portion 110 and second grip portion 112 haveidentical orders of symmetry about longitudinal symmetry axis 106. Thepreceding subject matter of this paragraph characterizes example 3 ofthe present disclosure, wherein example 3 also includes the subjectmatter according to example 2, above.

First grip portion 110 and second grip portion 112 having identicalorders of symmetry about longitudinal symmetry axis 106 enable firstgrip portion 110 and second grip portion 112 to be mounted in astandard, off-the-shelf material property testing apparatus (not shown;for example, a tensile-test machine) with little or no modificationrequired.

Referring generally to FIG. 1A and particularly to, e.g., FIGS. 2A, 2B,and 2C, intermediate portion 114 comprises gauge portion 120. Gaugeportion 120 has gauge-portion cross-section, perpendicular tolongitudinal symmetry axis 106. Gauge-portion cross-section is less thana cross-sectional area, perpendicular to longitudinal symmetry axis 106,of every portion of intermediate portion 114 other than gauge portion120. The preceding subject matter of this paragraph characterizesexample 4 of the present disclosure, wherein example 4 also includes thesubject matter according to example 2 or 3, above.

Gauge portion 120 provides a location of smallest cross-section alongtest coupon 900 (shown in FIG. 9) formed from monolithic precursor testcoupon 100. Gauge portion 120 thus provides an expected site of failureof test coupon 900 during material properties testing, and thecross-section of gauge portion 120 is usable, along with applied forcemeasurements from a standard, off-the-shelf material property testingapparatus (not shown; for example, a tensile-test machine), to calculatethe material properties of the material of test coupon 900.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 3A,surface 116 of intermediate portion 114 has, in a plane that containslongitudinal symmetry axis 106, first curvature 302, contiguous withfirst grip portion 110, second curvature 304, contiguous with secondgrip portion 112, and a linear profile, defining gauge portion 120 overgauge length 122 between first curvature 302 and second curvature 304.The preceding subject matter of this paragraph characterizes example 5of the present disclosure, wherein example 5 also includes the subjectmatter according to example 4, above.

First curvature 302, being contiguous with first grip portion 110,second curvature 304, being contiguous with second grip portion 112, andthe linear profile, positioned between first curvature 302 and secondcurvature 304 and defining gauge portion 120, facilitates forming gaugeportion 120 with a preselected stress profile, which simplifiescalculation of material properties from results of testing test coupon900 (shown in FIG. 9). In some examples, first curvature 302 is formedwith first radius of curvature 312 and second curvature 304 is formedwith second radius of curvature 314 that is substantially identical tofirst radius of curvature 312.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 3B,surface 116 of intermediate portion 114 has continuous curvature 306between first grip portion 110 and second grip portion 112 such thatgauge portion 120 lies in a plane, perpendicular to longitudinalsymmetry axis 106. The preceding subject matter of this paragraphcharacterizes example 6 of the present disclosure, wherein example 6also includes the subject matter according to example 4, above.

Continuous curvature 306 between first grip portion 110 and second gripportion 112, such that gauge portion 120 lies in a plane, perpendicularto longitudinal symmetry axis 106, facilitates forming gauge portion 120with a preselected stress profile, and further provides a relativelynarrow region in which test coupon 900 (shown in FIG. 9) is expected tofail during certain material property testing methods, which simplifiescalculation of material properties from results of testing test coupon900. In some examples, continuous curvature 306 is formed with a single,constant radius of curvature 316, between first grip portion 110 andsecond grip portion 112.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 4,intermediate portion 114 further comprises notch 400 and notch 400comprises gauge portion 120. The preceding subject matter of thisparagraph characterizes example 7 of the present disclosure, whereinexample 7 also includes the subject matter according to any one ofexamples 4 to 6, above.

Notch 400 provides a relatively narrow region in which test coupon 900(shown in FIG. 9) is expected to fail during certain material propertytesting methods, and also facilitates forming gauge portion 120 with apreselected stress profile, which simplifies calculation of materialproperties from results of testing test coupon 900.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 4, notch400 has, in a plane that contains longitudinal symmetry axis 106, one ofangular profile 402 along longitudinal symmetry axis 106, arcuateprofile 404 along longitudinal symmetry axis 106, or rectangular profile406 along longitudinal symmetry axis 106. The preceding subject matterof this paragraph characterizes example 8 of the present disclosure,wherein example 8 also includes the subject matter according to example7, above.

Notch 400 having one of one of angular profile 402, arcuate profile 404,or rectangular profile 406 further facilitates forming gauge portion 120with a preselected stress profile, which simplifies calculation ofmaterial properties from results of testing test coupon 900 (shown inFIG. 9).

Referring generally to FIG. 1A and particularly to, e.g., FIG. 4, notch400 is symmetrical about longitudinal symmetry axis 106. The precedingsubject matter of this paragraph characterizes example 9 of the presentdisclosure, wherein example 9 also includes the subject matter accordingto example 7 or 8, above.

Notch 400 being symmetrical about longitudinal symmetry axis 106facilitates forming gauge portion 120 with a preselected symmetricalstress profile, which simplifies calculation of certain materialproperties from results of testing test coupon 900 (shown in FIG. 9).

Referring generally to FIG. 1A and particularly to, e.g., FIG. 4, notch400 is asymmetrical about longitudinal symmetry axis 106. The precedingsubject matter of this paragraph characterizes example 10 of the presentdisclosure, wherein example 10 also includes the subject matteraccording to example 7 or 8, above.

Notch 400 being asymmetrical about longitudinal symmetry axis 106facilitates forming gauge portion 120 with a preselected stressconcentration in the asymmetric region, which simplifies calculation ofcertain material properties from results of testing test coupon 900(shown in FIG. 9).

Referring generally to FIG. 1A and particularly to, e.g., FIGS. 2A, 2B,and 2C, runners of one pair of runners 130, adjacent to each other, andrunners of any other pair of runners 130, adjacent to each other, haveequal angular separations about longitudinal symmetry axis 106. Thepreceding subject matter of this paragraph characterizes example 11 ofthe present disclosure, wherein example 11 also includes the subjectmatter according to any one of examples 2 to 10, above.

Runners 130 having equal angular separations about longitudinal symmetryaxis 106 facilitates increased stability of monolithic precursor testcoupon 100.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 5, totallength 500 of monolithic precursor test coupon 100, measured alonglongitudinal symmetry axis 106, is between about 10.1 cm (4 inches) andabout 30.5 cm (12 inches), and length 514 of intermediate portion 114 isbetween about 2.5 cm (1 inch) and about 15.2 cm (6 inches). Thepreceding subject matter of this paragraph characterizes example 12 ofthe present disclosure, wherein example 12 also includes the subjectmatter according to any one of examples 2 to 11, above.

In some examples, total length 500 and length 514 in the disclosedranges enable test coupon 900 (shown in FIG. 9) formed from monolithicprecursor test coupon 100 to be tested accurately in a standard,off-the-shelf material property testing apparatus (not shown; forexample, a tensile-test machine) with little or no modificationrequired.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 5, gripdiameter 510 of each of first grip portion 110 and second grip portion112 is between about 0.25 cm (0.1 inches) and about 3.0 cm (1.2 inches),and least diameter 515 of intermediate portion 114 is between about 0.51cm (0.2 inches) and about 1.52 cm (0.6 inches). The preceding subjectmatter of this paragraph characterizes example 13 of the presentdisclosure, wherein example 13 also includes the subject matteraccording to example 12, above.

In some examples, grip diameter 510 in the disclosed range enables testcoupon 900 (shown in FIG. 9) formed from monolithic precursor testcoupon 100 to be tested accurately in a standard, off-the-shelf materialproperty testing apparatus (not shown; for example, a tensile-testmachine) with little or no modification required.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 5, eachof runners 130 has, in a plane that contains longitudinal symmetry axis106, radius of curvature 530 between about 7.6 cm (3 inches) and about28.0 cm (11 inches). The preceding subject matter of this paragraphcharacterizes example 14 of the present disclosure, wherein example 14also includes the subject matter according to example 12 or 13, above.

In some examples, radius of curvature 530 in the disclosed rangeprovides sufficient separation between runners 130 and gauge portion 120to enable flash 180 (shown in FIG. 10E) to be removed from gauge portion120 before runners 130 are removed from monolithic precursor test coupon100 to form test coupon 900 (shown in FIG. 9).

Referring generally to FIG. 1A and particularly to, e.g., FIGS. 5 and 6,each of runners 130 defines runner thickness 531, measured in a plane,intersecting intermediate portion 114. Runner thickness 531 is betweenabout 0.25 cm (0.1 inches) and about 1.52 cm (0.6 inches). The precedingsubject matter of this paragraph characterizes example 15 of the presentdisclosure, wherein example 15 also includes the subject matteraccording to any one of examples 12 to 14, above.

In some examples, runner thickness 531 in the disclosed range enablesrunners 130 to provide structural stability to monolithic precursor testcoupon 100 to resist cracking or warping of monolithic precursor testcoupon 100 during one or more of: removal, in the green state, from amold, such as mold 800 (shown in FIG. 8A); de-binding; and sintering.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 2A,runners 130 are three in number. The preceding subject matter of thisparagraph characterizes example 16 of the present disclosure, whereinexample 16 also includes the subject matter according to any one ofexamples 1 to 15, above.

In some examples, runners 130 being three in number enables runners 130to provide structural stability to monolithic precursor test coupon 100to resist cracking or warping of monolithic precursor test coupon 100during one or more of: removal, in the green state, from a mold, such asmold 800 (shown in FIG. 8A); de-binding; and sintering.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 2B,runners 130 are two in number. The preceding subject matter of thisparagraph characterizes example 17 of the present disclosure, whereinexample 17 also includes the subject matter according to any one ofexamples 1 to 15, above.

In some examples, runners 130 being two in number enables runners 130 toprovide structural stability to monolithic precursor test coupon 100 toresist cracking or warping of monolithic precursor test coupon 100during one or more of: removal, in the green state, from a mold, such asmold 800 (shown in FIG. 8A); de-binding; and sintering.

Referring generally to FIG. 1A and particularly to, e.g., FIG. 2C,runners 130 are four in number. The preceding subject matter of thisparagraph characterizes example 18 of the present disclosure, whereinexample 18 also includes the subject matter according to any one ofexamples 1 to 15, above.

In some examples, runners 130 being four in number enables runners 130to provide structural stability to monolithic precursor test coupon 100to resist cracking or warping of monolithic precursor test coupon 100during one or more of: removal, in the green state, from a mold, such asmold 800 (shown in FIG. 8A); de-binding; and sintering.

Referring generally to FIG. 1A and particularly to, e.g., FIGS. 5 and 6,runners 130 are three or more in number, and runner width 533 increasesin radial direction 534 away from intermediate portion 114. Thepreceding subject matter of this paragraph characterizes example 19 ofthe present disclosure, wherein example 19 also includes the subjectmatter according to any one of examples 1 to 15, above.

In some examples, runner width 533 increasing in radial direction 534enables monolithic precursor test coupon 100 to be removed from mold 800(shown in FIG. 8A) along a parting plane of mold 800 withoutinterference from mold 800, while enabling runners 130 to providestructural stability to monolithic precursor test coupon 100 to resistcracking or warping of monolithic precursor test coupon 100 during oneor more of: removal, in the green state, from mold 800; de-binding; andsintering.

Referring generally to FIG. 1A and particularly to, e.g., FIGS. 5 and 6,each of runners 130 is spaced apart from intermediate portion 114 by gap532 along an entire extent of intermediate portion 114. The precedingsubject matter of this paragraph characterizes example 20 of the presentdisclosure, wherein example 20 also includes the subject matteraccording to any one of examples 1 to 19, above.

Gap 532 decreases a risk of damage to intermediate portion 114 during aprocess of removing runners 130 from monolithic precursor test coupon100 to form test coupon 900 (shown in FIG. 9).

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 7 and8A, 8B, 8E, and 8F, metal-injection-molding (MIM) apparatus 700 formaking monolithic precursor test coupon 100 is disclosed. MIM apparatus700 comprises mold 800, defining mold cavity 808. Mold cavity 808comprises first-grip-portion cavity 810 and second-grip-portion cavity812. Mold cavity 808 also comprises intermediate-portion cavity 814,interconnecting first-grip-portion cavity 810 and second-grip-portioncavity 812. Mold cavity 808 further comprises runner cavities 830,directly interconnecting first-grip-portion cavity 810 andsecond-grip-portion cavity 812 and not directly connected tointermediate-portion cavity 814. MIM apparatus 700 additionallycomprises injector 701, operable to inject feedstock material 750,comprising metal powder 748, into mold cavity 808 to form monolithicprecursor test coupon 100. The preceding subject matter of thisparagraph characterizes example 21 of the present disclosure.

MIM apparatus 700 enables homogeneous distribution of feedstock material750 within first-grip-portion cavity 810, intermediate-portion cavity814, and second-grip-portion cavity 812 to facilitate formation ofmonolithic precursor test coupon 100 in mold 800 with reduced oreliminated voids, and further with reduced or eliminated shearing ofbinder 749 that is included in feedstock material 750 along with metalpowder 748. More specifically, runner cavities 830 enable a portion offeedstock material 750 to bypass a flow restriction caused byintermediate-portion cavity 814 and provide back-fill of downstreamportions of monolithic precursor test coupon 100 (shown in FIG. 1A). Thebypass flow area provided by runner cavities 830 thus enables formationof monolithic precursor test coupon 100 having a proper distribution andintegrity of feedstock material 750 at an injection rate that avoidsproblems of binder shearing or premature binder cross-linking.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 8A, 8B,8E, and 8F, mold 800 comprises mold sections 860, shaped, when assembledtogether, to define mold cavity 808. The preceding subject matter ofthis paragraph characterizes example 22 of the present disclosure,wherein example 22 also includes the subject matter according to example21, above.

Mold sections 860 enable disassembly of mold 800 to facilitateextraction of monolithic precursor test coupon 100 (shown in FIG. 1A)from mold 800 after the injection process is complete.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 8A, 8B,and 8E, runner cavities 830 are three or more in number, and moldsections 860 each comprise two parting surfaces 870. Each of partingsurfaces 870 of one of mold sections 860 is shaped to abut a single oneof parting surfaces 870 of another one of mold sections 860 when moldsections 860 are assembled together. Each of runner cavities 830 isdefined between precisely two of mold sections 860. The precedingsubject matter of this paragraph characterizes example 23 of the presentdisclosure, wherein example 23 also includes the subject matteraccording to example 22, above.

In examples in which runner cavities 830 are three or more in number,runner cavities 830 each being defined between precisely two of moldsections 860 reduces or eliminates interference of runners 130 (shown inFIG. 1A) with mold sections 860 during disassembly of mold sections 860to remove monolithic precursor test coupon 100.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 8A, 8B,8E, and 8F, mold sections 860 are equal in number to runner cavities830. The preceding subject matter of this paragraph characterizesexample 24 of the present disclosure, wherein example 24 also includesthe subject matter according to example 22 or 23, above.

Mold sections 860 being equal in number to runner cavities 830 is aleast number of mold sections 860 that enables runner cavities 830 to bedefined between respective pairs of mold sections 860, which reduces oreliminates interference of runners 130 (shown in FIG. 1A) formed inrunner cavities 830 with mold sections 860 during disassembly of moldsections 860 to remove monolithic precursor test coupon 100.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 8B, 8C,and 8D, at least one of mold sections 860 comprises mold cavity wall866, oriented to define a boundary of mold cavity 808, and pin chamber862, defined in at least one of mold sections 860 and depending frommold cavity wall 866. MIM apparatus 700 further comprises ejector pin850, coupled to pin chamber 862 and selectively movable between,inclusively, a recessed position relative to pin chamber 862 and anextended position relative to pin chamber 862. Ejector pin 850 comprisespin head 852, having tapered lower surface 854 and upper surface 856,contiguous with tapered lower surface 854. Ejector pin 850, in therecessed position, is seated in pin chamber 862 so that upper surface856 of pin head 852 is flush with mold cavity wall 866. Ejector pin 850,in the extended position, extends from pin chamber 862 so that pin head852 is spaced from mold cavity wall 866. The preceding subject matter ofthis paragraph characterizes example 25 of the present disclosure,wherein example 25 also includes the subject matter according to any oneof examples 22 to 24, above.

Ejector pin 850 movable from the recessed position to the extendedposition facilitates separating monolithic precursor test coupon 100from mold sections 860 after mold sections 860 are disassembled forremoval of monolithic precursor test coupon 100. More specifically,moving ejector pin 850 from the recessed position to the extendedposition pushes monolithic precursor test coupon 100 away from moldcavity wall 866.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 8A-8F,upper surface 856 of pin head 852 is contoured to match a local contourof mold cavity wall 866. The preceding subject matter of this paragraphcharacterizes example 26 of the present disclosure, wherein example 26also includes the subject matter according to example 25, above.

Upper surface 856 of pin head 852 in the recessed position beingcontoured to match the local contour of mold cavity wall 866 facilitatesreducing or eliminating imperfections imprinted by ejector pin 850 on asurface of monolithic precursor test coupon 100 during the MIM process.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 7 and8A-8F, pin chamber 862 comprises tapered portion 864, contoured toreceive tapered lower surface 854 of pin head 852 in direct sealingcontact when ejector pin 850 is in the recessed position. The precedingsubject matter of this paragraph characterizes example 27 of the presentdisclosure, wherein example 27 also includes the subject matteraccording to example 25 or 26, above.

Tapered portion 864 of pin chamber 862 being contoured to receivetapered lower surface 854 of pin head 852 facilitates creating apositive seal between pin head 852 and mold cavity wall 866 wheninjection pressure is applied by MIM apparatus 700. More specifically,ejector pin 850 in the recessed position, positive pressure inside moldcavity 808 reacts against pin head 852 and tends to force ejector pin850 deeper into pin chamber 862, such that the greater the pressureinside mold cavity 808, the better the seal created between taperedlower surface 854 and tapered portion 864 of pin chamber 862.Accordingly, tapered portion 864 of pin chamber 862 tends to reduce oreliminate a potential for ejector pin 850 to become adhered in therecessed position, and thus inoperable to eject monolithic precursortest coupon 100, due to binder 749 seeping between pin head 852 and moldcavity wall 866 when MIM apparatus 700 applies pressure to mold cavity808.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 8A and8B, runner cavities 830 are three in number. The preceding subjectmatter of this paragraph characterizes example 28 of the presentdisclosure, wherein example 28 also includes the subject matteraccording to any one of examples 21 to 27, above.

Runner cavities 830 being three in number results in monolithicprecursor test coupon 100 being formed with three runners 130, whichprovides for more efficient back-fill of monolithic precursor testcoupon 100 and added stability to monolithic precursor test coupon 100formed in mold cavity 808, as compared to runner cavities 830 beingfewer than three in number.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 8F,runner cavities 830 are two in number. The preceding subject matter ofthis paragraph characterizes example 29 of the present disclosure,wherein example 29 also includes the subject matter according to any oneof examples 21 to 27, above.

Runner cavities 830 being two in number enables mold 800 to be assembledfrom as few as two mold sections 860, which results in a simpler molddesign as compared to runner cavities 830 being greater than two innumber.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 8E,runner cavities 830 are four in number. The preceding subject matter ofthis paragraph characterizes example 30 of the present disclosure,wherein example 30 also includes the subject matter according to any oneof examples 21 to 27, above.

Runner cavities 830 being four in number results in monolithic precursortest coupon 100 being formed with four runners 130, which provides formore efficient back-fill of monolithic precursor test coupon 100 andadded stability to monolithic precursor test coupon 100 formed in moldcavity 808, as compared to runner cavities 830 being fewer than four innumber.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 7, 8A,8B, 8E, and 8F, mold 800 further defines sacrificial cavity 840 indownstream flow communication with mold cavity 808. The precedingsubject matter of this paragraph characterizes example 31 of the presentdisclosure, wherein example 31 also includes the subject matteraccording to any one of examples 21 to 30, above.

Sacrificial cavity 840 provides a space for impurities and/or airinitially present in mold cavity 808 and/or feedstock material 750 to beexpelled from mold cavity 808 at a downstream location as additional anadditional amount of feedstock material 750 continues to be injectedinto mold cavity 808 at an upstream location. For example, feedstockmaterial 750 may initially be at a temperature that partially meltsbinder 749 out of feedstock material 750, which would undesirably altera material property of monolithic precursor test coupon 100. The initialportion of feedstock material 750 is forced through mold cavity 808 intosacrificial cavity 840 as the temperature of feedstock material 750 isadjusted, enabling mold cavity 808 to be filled with feedstock material750 having reduced or eliminated melt-out of binder 749.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 7, 8A,8B, 8E, and 8F, downstream end 842 of sacrificial cavity 840 is closed.The preceding subject matter of this paragraph characterizes example 32of the present disclosure, wherein example 32 also includes the subjectmatter according to example 31, above.

Downstream end 842 of sacrificial cavity 840 being closed reduces oreliminates the need for capturing and handling feedstock material 750,expelled during the MIM process.

Referring generally to FIG. 1B and particularly to, e.g., FIGS.7, 8A,8B, 8E, and 8F, downstream end 842 of sacrificial cavity 840 is open.The preceding subject matter of this paragraph characterizes example 33of the present disclosure, wherein example 33 also includes the subjectmatter according to example 31, above.

Downstream end 842 of sacrificial cavity 840 being open facilitatesinspection and evaluation of a quality of feedstock material 750,expelled during the MIM process to enable estimation of a quality offeedstock material 750, currently filling mold cavity 808. Downstreamend 842 of sacrificial cavity 840 being open also enables an unlimitedamount of feedstock material 750 to be expelled during the MIM processuntil a selected quality threshold is achieved.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7, 8A,8B, 8E, and 8F, injector 701 comprises barrel 702, configured to receivefeedstock material 750. Injector 701 also comprises press 703, operableto force feedstock material 750 from barrel 702 through injection port802 of mold 800 into first-grip-portion cavity 810. Press 703 is furtheroperable to force feedstock material 750 from first-grip-portion cavity810, in parallel through intermediate-portion cavity 814 and runnercavities 830, into second-grip-portion cavity 812. The preceding subjectmatter of this paragraph characterizes example 34 of the presentdisclosure, wherein example 34 also includes the subject matteraccording to any one of examples 21 to 33, above.

Barrel 702 and press 703 cooperate to provide a controllably pressurizeddelivery of feedstock material 750 into mold cavity 808. For example,barrel 702 is in flow communication with hopper 718. Feedstock material750 is gravity-fed into hopper 718 and flows into barrel 702. After asuitable initial fill of barrel 702 with feedstock material 750, press703 is operated to inject feedstock material 750 into mold cavity 808.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7, press703 comprises cylinder 710, selectively fillable with pressurized fluid708. Press 703 also comprises piston head 706, located within cylinder710 and translatable toward barrel 702 in response to receipt ofpressurized fluid 708 in cylinder 710. Press 703 further comprisespiston rod 704, extending from piston head 706 out of cylinder 710 intobarrel 702 and shaped to force feedstock material 750 from barrel 702through injection port 802 in response to translation of piston head 706toward barrel 702. The preceding subject matter of this paragraphcharacterizes example 35 of the present disclosure, wherein example 35also includes the subject matter according to example 34, above.

Piston head 706, piston rod 704, and cylinder 710 cooperate to provide ahydraulically controllable pressurization mechanism to implement press703.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7, MIMapparatus 700 further comprises feedstock heater 721, operable to heatfeedstock material 750 in barrel 702. The preceding subject matter ofthis paragraph characterizes example 36 of the present disclosure,wherein example 36 also includes the subject matter according to example34 or 35, above.

Feedstock heater 721 facilitates heating feedstock material 750 towithin a temperature range that is sufficiently high to enable suitableflow of feedstock material 750 through mold cavity 808, yet notsufficiently high to melt binder 749 out of feedstock material 750 andnot sufficiently high to cross-link and solidify binder 749 prior toadequate fill of mold cavity 808.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7,feedstock heater 721 comprises resistance heater 720, coupled to barrel702. The preceding subject matter of this paragraph characterizesexample 37 of the present disclosure, wherein example 37 also includesthe subject matter according to example 36, above.

Resistance heater 720 coupled to barrel 702 provides an electricallycontrollable heating mechanism to implement feedstock heater 721.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7, MIMapparatus 700 further comprises barrel 702, configured to receivefeedstock material 750. MIM apparatus 700 also comprises screw 711,operable to advance feedstock material 750 through barrel 702 towardmold 800 and to compact feedstock material 750, adjacent to mold 800.The preceding subject matter of this paragraph characterizes example 38of the present disclosure, wherein example 38 also includes the subjectmatter according to any one of examples 21 to 37, above.

Barrel 702 and screw 711 cooperate to provide an efficient mechanism tocompact feedstock material 750 received in barrel 702, for example fromhopper 718, adjacent to mold 800.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7,injector 701 comprises piston rod 704, extending into barrel 702 andshaped to force feedstock material 750 from barrel 702 through injectionport 802 of mold 800. Screw 711 comprises thread 712, located on anouter surface of piston rod 704. Screw 711 also comprises motor 714,operable to rotate piston rod 704. The preceding subject matter of thisparagraph characterizes example 39 of the present disclosure, whereinexample 39 also includes the subject matter according to example 38,above.

Thread 712 on the outer surface of piston rod 704, wherein piston rod704 is rotatable by motor 714 and also is shaped to force feedstockmaterial 750 from barrel 702 into mold 800, provides a spatially compactand efficient mechanism to implement screw 711. For example, motor 714is operable to selectively rotationally drive piston rod 704 through acooperating gear 716, affixed to piston rod 704. In someimplementations, piston rod 704 further is selectively linearly drivableby hydraulic action on piston head 706 positioned within cylinder 710,as described above, further enhancing spatial compactness andefficiency.

In other examples, screw 711 is implemented independently of piston rod704.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7, MIMapparatus 700 further comprises mold heater 791, operable to heat mold800. The preceding subject matter of this paragraph characterizesexample 40 of the present disclosure, wherein example 40 also includesthe subject matter according to any one of examples 21 to 39, above.

Mold heater 791 facilitates maintaining feedstock material 750 duringinjection within the temperature range that is sufficiently high toenable suitable flow of feedstock material 750 through mold cavity 808,yet not sufficiently high to melt binder 749 out of feedstock material750 and not sufficiently high to cross-link and solidify binder 749prior to adequate fill of mold cavity 808. For example, mold heater 791is operable to maintain feedstock material 750, during injection, atapproximately the same temperature initially induced by feedstock heater721 while feedstock material 750 is in barrel 702.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 7, and8A, 8B, 8E, and 8F, mold heater 791 comprises at least one channel 890,defined in mold 800. Mold heater 791 also comprises at least one heatexchanger 790, operable to heat fluid 792 circulated through at leastone channel 890. The preceding subject matter of this paragraphcharacterizes example 41 of the present disclosure, wherein example 41also includes the subject matter according to example 40, above.

Heat exchanger 790 operable to heat fluid 792 circulated through atleast one channel 890 provides a controllable heating mechanism toimplement mold heater 791. For example, at least one channel 890 isimplemented as a plurality of channels, with a respective one of atleast one channel 890 extending through each of mold sections 860 tofacilitate consistent heating among mold sections 860.

Referring generally to FIG. 1B and particularly to, e.g., FIG. 7, MIMapparatus 700 further comprises mold cooler 793, operable to cool mold800. The preceding subject matter of this paragraph characterizesexample 42 of the present disclosure, wherein example 42 also includesthe subject matter according to any one of examples 21 to 41, above.

After injection of feedstock material 750 is complete, mold cooler 793facilitates cooling feedstock material 750 within mold cavity 808 tofacilitate removal of monolithic precursor test coupon 100 from moldcavity 808. For example, cooling of feedstock material 750 facilitateshandling of monolithic precursor test coupon 100 after formation in mold800, and also tends to cause monolithic precursor test coupon 100 toshrink, which facilitates separation of monolithic precursor test coupon100 from mold cavity wall 866.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 7, 8A,8B, 8E, and 8F, mold cooler 793 comprises at least one channel 890,defined in mold 800. Mold cooler 793 also comprises at least one heatexchanger 790, operable to cool fluid 792, circulated through at leastone channel 890. The preceding subject matter of this paragraphcharacterizes example 43 of the present disclosure, wherein example 43also includes the subject matter according to example 42, above.

Heat exchanger 790 operable to cool fluid 792 circulated through atleast one channel 890 provides a controllable cooling mechanism toimplement mold cooler 793. For example, at least one channel 890 isimplemented as a plurality of channels, with a respective one of atleast one channel 890 extending through each of mold sections 860 tofacilitate consistent cooling among mold sections 860. In someimplementations, heat exchanger 790 is also operable to heat fluid 792circulated through at least one channel 890, as described above,enabling both heating and cooling of mold 800 to be implemented by thesame ones of heat exchanger 790 and at least one channel 890, enhancingspatial compactness and efficiency of MIM apparatus 700.

Referring generally to FIG. 1B and particularly to, e.g., FIGS. 8A, 8B,8E, and 8F, first-grip-portion cavity 810, intermediate-portion cavity814, and second-grip-portion cavity 812 are arranged in series alonglongitudinal mold-cavity axis 806. Intermediate-portion cavity 814comprises gauge-portion cavity 820, defining a gauge cross-sectionalflow area, perpendicular to longitudinal mold-cavity axis 806. The gaugecross-sectional flow area is a least value of a set of values ofcross-sectional flow areas, perpendicular to longitudinal mold-cavityaxis 806 at all locations along first-grip-portion cavity 810,intermediate-portion cavity 814, and second-grip-portion cavity 812. Thepreceding subject matter of this paragraph characterizes example 44 ofthe present disclosure, wherein example 44 also includes the subjectmatter according to any one of examples 21 to 43, above.

The gauge cross-sectional flow area being a least value of a set ofvalues of cross-sectional flow areas at all locations alongfirst-grip-portion cavity 810, intermediate-portion cavity 814, andsecond-grip-portion cavity 812 creates gauge portion 120 of monolithicprecursor test coupon 100 (shown in FIG. 1) as an expected site offailure of test coupon 900 (shown in FIG. 9) during material propertiestesting. The cross-section of gauge portion 120 is usable, along withapplied force measurements from a standard, off-the-shelf materialproperty testing apparatus (not shown; for example, a tensile-testmachine), to calculate the material properties of the material of testcoupon 900.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A-10E,flash-removal tool 1000 is disclosed. Flash-removal tool 1000 comprisestool body 1002, extending along longitudinal tool axis 1004.Flash-removal tool 1000 also comprises tooth 1010, projecting from toolbody 1002 in first direction 1090. Flash-removal tool 1000 furthercomprises engagement surface 1020, located preselected distance 1022away from tooth 1010 along longitudinal tool axis 1004 and perpendicularto longitudinal tool axis 1004. Tooth 1010 comprises shearing surface1014, facing in first direction 1090 and located offset distance 1012away from longitudinal tool axis 1004 in second direction 1092. Firstdirection 1090 and second direction 1092 are orthogonal to each otherand define a plane, perpendicular to longitudinal tool axis 1004. Thepreceding subject matter of this paragraph characterizes example 45 ofthe present disclosure.

Engagement surface 1020 being located preselected distance 1022 awayfrom tooth 1010 enables tooth 1010 to align longitudinally with gaugeportion 120 when engagement surface 1020 engages monolithic precursortest coupon 100 (shown in FIG. 1). Moreover, tooth 1010 projecting fromtool body 1002 in first direction 1090 and having shearing surface 1014,located offset distance 1012 away from longitudinal tool axis 1004 insecond direction 1092 enables tooth 1010 to slide between runners 130(shown in FIG. 1) of monolithic precursor test coupon 100 such thatshearing surface 1014 aligns precisely with flash 180 on gauge portion120. Thus, flash-removal tool 1000 facilitates removal of flash 180 fromgauge portion 120, while runners 130 are still attached to monolithicprecursor test coupon 100, without requiring complex alignmentprocedures or adjustments.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A-10E,engagement surface 1020 is defined on tool body 1002, such thatpreselected distance 1022 is non-adjustable. The preceding subjectmatter of this paragraph characterizes example 46 of the presentdisclosure, wherein example 46 also includes the subject matteraccording to example 45, above.

Preselected distance 1022 being non-adjustable simplifies manufactureand facilitates the use of flash-removal tool 1000. For example,monolithic precursor test coupon 100 is manufactured such that firstprecursor-coupon end 102 is separated from gauge portion 120 (shown inFIG. 1) by a standard longitudinal distance, and flash-removal tool 1000is manufactured having preselected distance 1022 that is non-adjustableand equal to the standard longitudinal distance from firstprecursor-coupon end 102 to gauge portion 120.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10C, flash-removal tool 1000 further comprises extendable portion 1041,movable with respect to tool body 1002 to adjust preselected distance1022. The preceding subject matter of this paragraph characterizesexample 47 of the present disclosure, wherein example 47 also includesthe subject matter according to example 45 or 46, above.

Preselected distance 1022 being adjustable, via extendable portion 1041movable with respect to tool body 1002, facilitates adaptability offlash-removal tool 1000 to monolithic precursor test coupon 100 (shownin FIG. 1) having various sizes. For example, monolithic precursor testcoupon 100 is manufactured in different longitudinal sizes correspondingto different sizes of test coupon 900 needed for use with differentmaterial property testing machines (not shown). Preselected distance1022 being adjustable enables a single tool, such as flash-removal tool1000, to be used with more than one size of monolithic precursor testcoupon 100.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10C, extendable portion 1041 comprises telescoping portion 1040, coupledto tool body 1002. Engagement surface 1020 is defined on telescopingportion 1040. The preceding subject matter of this paragraphcharacterizes example 48 of the present disclosure, wherein example 48also includes the subject matter according to example 47, above.

Telescoping portion 1040 coupled to tool body 1002 provides amechanically simple and effective structure for implementation ofextendable portion 1041.

Referring generally to FIG. 1C and particularly to, e.g., FIG. 10A and10C, flash-removal tool 1000 further comprises lock 1043, operable toselectively lock telescoping portion 1040 in position relative to toolbody 1002 after preselected distance 1022 is adjusted. The precedingsubject matter of this paragraph characterizes example 49 of the presentdisclosure, wherein example 49 also includes the subject matteraccording to example 48, above.

Lock 1043 promotes stability and ease of use of flash-removal tool 1000,having preselected distance 1022 that is adjustable.

Referring generally to FIG. 1C and particularly to, e.g., FIG. 10A, lock1043 comprises detent 1044, located on one of telescoping portion 1040or tool body 1002, and plurality of catches 1046, arrangedlongitudinally on another of telescoping portion 1040 or tool body 1002.Each one of catches 1046 is configured to interfere with detent 1044when telescoping portion 1040 is correspondingly adjusted relative totool body 1002. The preceding subject matter of this paragraphcharacterizes example 50 of the present disclosure, wherein example 50also includes the subject matter according to example 49, above.

Detent 1044 and catches 1046 provides a mechanically simple andeffective structure for implementation of lock 1043.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A-10C,flash-removal tool 1000 further comprises positioning groove 1006,defined in tool body 1002. Positioning groove 1006 extendslongitudinally between engagement surface 1020 and tooth 1010 and facesin first direction 1090. The preceding subject matter of this paragraphcharacterizes example 51 of the present disclosure, wherein example 51also includes the subject matter according to any one of examples 45 to50, above

Positioning groove 1006 facilitates stable positioning of flash-removaltool 1000 against monolithic precursor test coupon 100 (shown in FIG.1).

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A-10C,engagement surface 1020 forms longitudinal end-wall 1034 of positioninggroove 1006. The preceding subject matter of this paragraphcharacterizes example 52 of the present disclosure, wherein example 52also includes the subject matter according to example 51, above.

Engagement surface 1020 forming longitudinal end-wall 1034 ofpositioning groove 1006 combines the mechanism for longitudinallypositioning tooth 1010 within an additional mechanism for stablepositioning of flash-removal tool 1000 against monolithic precursor testcoupon 100 (shown in FIG. 1), facilitating a compact design forflash-removal tool 1000.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A-10C,positioning groove 1006 comprises cylindrically contoured portion 1030,extending parallel to longitudinal tool axis 1004. The preceding subjectmatter of this paragraph characterizes example 53 of the presentdisclosure, wherein example 53 also includes the subject matteraccording to example 51 or 52, above.

Cylindrically contoured portion 1030 of positioning groove 1006facilitates stable positioning of flash-removal tool 1000 against firstgrip portion 110 of monolithic precursor test coupon 100 (shown inFIG. 1) for implementations in which first grip portion 110 has acylindrical profile complementary to cylindrically contoured portion1030.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A-10C,positioning groove 1006 further comprises tapered portion 1032,extending longitudinally between cylindrically contoured portion 1030and tooth 1010 and parallel to longitudinal tool axis 1004. Thepreceding subject matter of this paragraph characterizes example 54 ofthe present disclosure, wherein example 54 also includes the subjectmatter according to example 53, above.

Tapered portion 1032 of positioning groove 1006 facilitates stablepositioning of flash-removal tool 1000 against intermediate portion 114of monolithic precursor test coupon 100 (shown in FIG. 1) forimplementations in which intermediate portion 114, adjacent to firstgrip portion 110, has a longitudinally tapering profile complementary totapered portion 1032.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10C, flash-removal tool 1000 further comprises secondary groove 1035,defined in tool body 1002. Tooth 1010 divides tool body 1002longitudinally into two sides. Positioning groove 1006 extendslongitudinally on one of the two sides, and secondary groove 1035extends longitudinally on another of the two sides and faces in firstdirection 1090. The preceding subject matter of this paragraphcharacterizes example 55 of the present disclosure, wherein example 55also includes the subject matter according to any one of examples 51 to54, above.

Secondary groove 1035 further facilitates stable positioning offlash-removal tool 1000 against monolithic precursor test coupon 100(shown in FIG. 1).

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10C, secondary groove 1035 comprises cylindrically contoured secondaryportion 1036, extending parallel to longitudinal tool axis 1004. Thepreceding subject matter of this paragraph characterizes example 56 ofthe present disclosure, wherein example 56 also includes the subjectmatter according to example 55, above.

Cylindrically contoured secondary portion 1036 of secondary groove 1035facilitates stable positioning of flash-removal tool 1000 against secondgrip portion 112 of monolithic precursor test coupon 100 (shown inFIG. 1) for implementations in which second grip portion 112 has acylindrical profile complementary to cylindrically contoured secondaryportion 1036.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10C, secondary groove 1035 further comprises tapered secondary portion1038, parallel to longitudinal tool axis 1004 and extendinglongitudinally between cylindrically contoured secondary portion 1036and tooth 1010. The preceding subject matter of this paragraphcharacterizes example 57 of the present disclosure, wherein example 57also includes the subject matter according to example 56, above.

Tapered secondary portion 1038 of secondary groove 1035 facilitatesstable positioning of flash-removal tool 1000 against intermediateportion 114 of monolithic precursor test coupon 100 (shown in FIG. 1)for implementations in which intermediate portion 114, adjacent tosecond grip portion 112, has a longitudinally tapering profilecomplementary to tapered secondary portion 1038.

Referring generally to FIG. 1C and particularly to, e.g., FIG. 10B,flash-removal tool 1000 further comprises second tooth 1011.Longitudinal tool axis 1004 is located between tooth 1010 and secondtooth 1011. The preceding subject matter of this paragraph characterizesexample 58 of the present disclosure, wherein example 58 also includesthe subject matter according to any one of examples 45 to 57, above.

Second tooth 1011 positioned opposite tooth 1010 facilitates removal ofmultiple portions of flash 180 (shown in FIG. 10E) without requiringdisengagement of flash-removal tool 1000 from monolithic precursor testcoupon 100 (shown in FIG. 1) and subsequent re-positioning offlash-removal tool 1000 to re-position tooth 1010.

Referring generally to FIG. 1C and particularly to, e.g., FIG. 10B,second tooth 1011 is located preselected distance 1022 away fromengagement surface 1020 along longitudinal tool axis 1004. The precedingsubject matter of this paragraph characterizes example 59 of the presentdisclosure, wherein example 59 also includes the subject matteraccording to example 58, above.

Engagement surface 1020 being located preselected distance 1022 awayfrom second tooth 1011 enables second tooth 1011 to align longitudinallywith gauge portion 120, simultaneously to tooth 1010 aligninglongitudinally with gauge portion 120, when engagement surface 1020engages monolithic precursor test coupon 100 (shown in FIG. 1).

Referring generally to FIG. 1C and particularly to, e.g., FIG. 10B,tooth 1010 is monolithic with tool body 1002. The preceding subjectmatter of this paragraph characterizes example 60 of the presentdisclosure, wherein example 60 also includes the subject matteraccording to any one of examples 45 to 59, above.

Tooth 1010 being monolithic with tool body 1002 simplifies manufactureof flash-removal tool 1000.

Referring generally to FIG. 1C and particularly to, e.g., FIG. 10A,tooth 1010 is formed separately from, and coupled to, tool body 1002.The preceding subject matter of this paragraph characterizes example 61of the present disclosure, wherein example 61 also includes the subjectmatter according to any one of examples 45 to 59, above.

Tooth 1010 being formed separately from, and coupled to, tool body 1002facilitates manufacture of flash-removal tool 1000 having variouslongitudinal sizes from standard elements used to form tool body 1002and tooth 1010.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10B, tool body 1002 extends along longitudinal tool axis 1004 from firstend 1050 to second end 1052. Engagement surface 1020 is located adjacentto first end 1050. The preceding subject matter of this paragraphcharacterizes example 62 of the present disclosure, wherein example 62also includes the subject matter according to any one of examples 45 to61, above.

Engagement surface 1020 being located adjacent to first end 1050 offlash-removal tool 1000 facilitates a compact design for flash-removaltool 1000.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10B, tooth 1010 is located at second end 1052. The preceding subjectmatter of this paragraph characterizes example 63 of the presentdisclosure, wherein example 63 also includes the subject matteraccording to example 62, above.

Tooth 1010 being located at second end 1052 of flash-removal tool 1000facilitates a compact design for flash-removal tool 1000.

Referring generally to FIG. 1C and particularly to, e.g., FIGS. 10A and10B, tooth 1010 is spaced apart from second end 1052 along longitudinaltool axis 1004. The preceding subject matter of this paragraphcharacterizes example 64 of the present disclosure, wherein example 64also includes the subject matter according to example 62, above.

Tooth 1010 being spaced apart longitudinally from second end 1052 offlash-removal tool 1000 facilitates stability of coupling flash-removaltool 1000 to monolithic precursor test coupon 100 (shown in FIG. 1). Forexample, secondary groove 1035 is included in the longitudinal portionof tool body 1002 between tooth 1010 and second end 1052.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS.2A-2C, 8A-8F, and 9, method 1100 of making test coupon 900 using mold800 is disclosed. Mold 800 defines mold cavity 808 that comprisesfirst-grip-portion cavity 810, second-grip-portion cavity 812, andintermediate-portion cavity 814, interconnecting first-grip-portioncavity 810 and second-grip-portion cavity 812. Mold cavity 808 furthercomprises runner cavities 830, directly interconnectingfirst-grip-portion cavity 810 and second-grip-portion cavity 812 and notdirectly connected to intermediate-portion cavity 814. Method 1100comprises (block 1118) injecting feedstock material 750, comprisingmetal powder 748, into mold cavity 808 to form monolithic precursor testcoupon 100 in mold cavity 808. Monolithic precursor test coupon 100comprises first grip portion 110, having a shape complementary to thatof first-grip-portion cavity 810, and second grip portion 112, having ashape complementary to that of second-grip-portion cavity 812.Monolithic precursor test coupon 100 also comprises intermediate portion114, having a shape complementary to that of intermediate-portion cavity814, and runners 130, each having a shape complementary to that of acorresponding one of runner cavities 830. Method 1100 also comprises(block 1142) removing runners 130 from monolithic precursor test coupon100. The preceding subject matter of this paragraph characterizesexample 65 of the present disclosure.

Method 1100 enables homogeneous distribution of feedstock material 750within first-grip-portion cavity 810, intermediate-portion cavity 814,and second-grip-portion cavity 812 to facilitate formation of monolithicprecursor test coupon 100 in mold 800 with reduced or eliminated voids,and further with reduced or eliminated shearing of binder 749 that isincluded in feedstock material 750 along with metal powder 748. Morespecifically, runner cavities 830 enable a portion of feedstock material750 to bypass a flow restriction, caused by intermediate-portion cavity814 and provide back-fill of downstream portions of monolithic precursortest coupon 100 (shown in FIG. 1A). The bypass flow area provided byrunner cavities 830 thus enables formation of monolithic precursor testcoupon 100 having a proper distribution and integrity of feedstockmaterial 750 at an injection rate that avoids problems of bindershearing or premature binder cross-linking. Removal of runners 130 frommonolithic precursor test coupon 100 leaves first grip portion 110,intermediate portion 114, and second grip portion 112 of test coupon 900for material property testing, such as in a tensile-test machine (notshown).

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS. 7,8A, 8B, 8E, and 8F, according to method 1100, (block 1118) injectingfeedstock material 750 into mold cavity 808 comprises (block 1120)pressurizing feedstock material 750 in barrel 702. Feedstock material750 is forced from barrel 702, through injection port 802 of mold 800,into first-grip-portion cavity 810 and then from first-grip-portioncavity 810, in parallel through intermediate-portion cavity 814 andrunner cavities 830, into second-grip-portion cavity 812. The precedingsubject matter of this paragraph characterizes example 66 of the presentdisclosure, wherein example 66 also includes the subject matteraccording to example 65, above.

Barrel 702 provides a suitable supply structure in which to pressurizefeedstock material 750 to cause injection of feedstock material 750 intomold cavity 808. For example, barrel 702 is in flow communication withhopper 718. Feedstock material 750 is gravity-fed into hopper 718 andflows into barrel 702. After a suitable initial fill of barrel 702 withfeedstock material 750, feedstock material 750 is pressurized to causeinjection of feedstock material 750 into mold cavity 808. Runnercavities 830 provide flow paths for feedstock material 750 that isinjected in parallel to intermediate-portion cavity 814 to facilitateback-fill of downstream portions of monolithic precursor test coupon 100(shown in FIG. 1A).

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIG.7,according to method 1100, (block 1120) pressurizing feedstock material750 in barrel 702 comprises (block 1122) applying hydraulic pressure tofeedstock material 750. The preceding subject matter of this paragraphcharacterizes example 67 of the present disclosure, wherein example 67also includes the subject matter according to example 66, above.

Hydraulic pressurization provides a suitably controllable pressurizationmechanism to inject feedstock material 750. For example, piston head 706is located within cylinder 710 and is translatable toward barrel 702 inresponse to receipt of pressurized fluid 708 (e.g., hydraulic fluid orwater) in cylinder 710. Piston rod 704, extending from piston head 706out of cylinder 710 into barrel 702, is shaped to force feedstockmaterial 750 from barrel 702 through injection port 802 in response tothe hydraulically pressurized translation of piston head 706 towardbarrel 702.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIG. 7,method 1100 further comprises (block 1104) heating feedstock material750 before (block 1118) injecting feedstock material 750 into moldcavity 808. The preceding subject matter of this paragraph characterizesexample 68 of the present disclosure, wherein example 68 also includesthe subject matter according to example 66 or 67, above.

Heating feedstock material 750 before injecting feedstock material 750into mold cavity 808 facilitates having feedstock material 750 within atemperature range that is sufficiently high to enable suitable flow offeedstock material 750 through mold cavity 808, yet not sufficientlyhigh to melt binder 749 out of feedstock material 750 and notsufficiently high to cross-link and solidify binder 749 prior toadequate fill of mold cavity 808.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIG. 7,method 1100 further comprises (block 1102) receiving feedstock material750 in barrel 702. Method 1100 also comprises, before (block 1118)injecting feedstock material 750 into mold cavity 808, (block 1106)advancing feedstock material 750 through barrel 702 toward mold 800.Feedstock material 750 is compacted adjacent to mold 800. The precedingsubject matter of this paragraph characterizes example 69 of the presentdisclosure, wherein example 69 also includes the subject matteraccording to any one of examples 65 to 68, above.

Advancing feedstock material 750 through barrel 702 to compact feedstockmaterial 750 adjacent to mold 800 reduces air pockets in, and increaseshomogeneity of, feedstock material 750 before injection of feedstockmaterial 750 into mold cavity 808. For example, screw 711 positionedwithin barrel 702 advances feedstock material 750 received from hopper718 toward, and compacts feedstock material 750 adjacent to, mold 800.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIG. 7,method 1100 further comprises (block 1108) heating mold 800 before(block 1118) injecting feedstock material 750 into mold cavity 808. Thepreceding subject matter of this paragraph characterizes example 70 ofthe present disclosure, wherein example 70 also includes the subjectmatter according to any one of examples 65 to 69, above.

Heating mold 800 facilitates maintaining feedstock material 750 duringinjection within the temperature range that is sufficiently high toenable suitable flow of feedstock material 750 through mold cavity 808,yet not sufficiently high to melt binder 749 out of feedstock material750 and not sufficiently high to cross-link and solidify binder 749prior to adequate fill of mold cavity 808. For example, mold 800 isheated to a temperature that, during injection, maintains feedstockmaterial 750 at approximately the same temperature initially induced byheating feedstock material 750 in barrel 702.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS. 7,8A, 8B, 8E, and 8F, according to method 1100, (block 1108) heating mold800 comprises (block 1110) circulating fluid 792 through at least oneheat exchanger 790 and through at least one channel 890, defined in mold800. The preceding subject matter of this paragraph characterizesexample 71 of the present disclosure, wherein example 71 also includesthe subject matter according to example 70, above.

Circulating fluid 792 through heat exchanger 790 and through at leastone channel 890 defined in mold 800 provides a controllable heatingmechanism to heat mold 800. For example, at least one channel 890 isimplemented as a plurality of channels, with a respective one of atleast one channel 890 extending through each of mold sections 860 tofacilitate consistent heating among mold sections 860.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIG. 7,method 1100 further comprises (block 1112) cooling mold 800 after (block1118) injecting feedstock material 750 into mold cavity 808. Thepreceding subject matter of this paragraph characterizes example 72 ofthe present disclosure, wherein example 72 also includes the subjectmatter according to any one of examples 65 to 71, above.

Cooling mold 800, after injection of feedstock material 750 is complete,facilitates cooling feedstock material 750 within mold cavity 808 tofacilitate removal of monolithic precursor test coupon 100 from moldcavity 808. For example, cooling of feedstock material 750 facilitateshandling of monolithic precursor test coupon 100 after formation in mold800, and also tends to cause monolithic precursor test coupon 100 toshrink, which facilitates separation of monolithic precursor test coupon100 from mold cavity wall 866.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS. 7,8A, 8B, 8E, and 8F, according to method 1100, (block 1112) cooling mold800 comprises (block 1114) circulating fluid 792 through at least oneheat exchanger 790 and through at least one channel 890, defined in mold800. The preceding subject matter of this paragraph characterizesexample 73 of the present disclosure, wherein example 73 also includesthe subject matter according to example 72, above.

Circulating fluid 792 through heat exchanger 790 and through at leastone channel 890 defined in mold 800 provides a controllable coolingmechanism to cool mold 800. For example, at least one channel 890 isimplemented as a plurality of channels, with a respective one of atleast one channel 890 extending through each of mold sections 860 tofacilitate consistent cooling among mold sections 860.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS. 7,8A, 8B, 8E, and 8F, according to method 1100, (block 1118) injectingfeedstock material 750 into mold cavity 808 comprises (block 1126)forcing a portion of feedstock material 750 out of mold cavity 808 intosacrificial cavity 840 in downstream flow communication with mold cavity808. The preceding subject matter of this paragraph characterizesexample 74 of the present disclosure, wherein example 74 also includesthe subject matter according to any one of examples 65 to 73, above.

Forcing a portion of feedstock material 750 out of mold cavity 808 intosacrificial cavity 840 enables impurities and/or air initially presentin mold cavity 808 and/or feedstock material 750 to be expelled frommold cavity 808 at a downstream location as an additional amount offeedstock material 750 continues to be injected into mold cavity 808 atan upstream location. For example, feedstock material 750 may initiallybe at a temperature that partially melts binder 749 out of feedstockmaterial 750, which would undesirably alter a material property ofmonolithic precursor test coupon 100. The initial portion of feedstockmaterial 750 is forced through mold cavity 808 into sacrificial cavity840 as the temperature of feedstock material 750 is adjusted, enablingmold cavity 808 to be filled with feedstock material 750 having reducedor eliminated melt-out of binder 749. In some examples, sacrificialcavity 840 has downstream end 842 open, and feedstock material 750flowing through downstream end 842 is observed to determine whetheradjustment of, e.g., the temperature of feedstock material 750 in barrel702 and/or other parameters that affect a quality of feedstock material750, is needed.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS. 7and 8A-8F, method 1100 further comprises, after (block 1118) injectingfeedstock material 750 into mold cavity 808, (block 1130) separatingmold sections 860 of mold 800 along at least one of parting surfaces 870and (block 1132) extending ejector pin 850 from at least one of moldsections 860 into mold cavity 808, such that monolithic precursor testcoupon 100 separates from mold 800. The preceding subject matter of thisparagraph characterizes example 75 of the present disclosure, whereinexample 75 also includes the subject matter according to any one ofexamples 65 to 74, above.

Extending ejector pin 850 into mold cavity 808 facilitates separatingmonolithic precursor test coupon 100 from mold sections 860 after moldsections 860 are disassembled for removal of monolithic precursor testcoupon 100. More specifically, extending ejector pin 850 into moldcavity 808 pushes monolithic precursor test coupon 100 away from moldcavity wall 866.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIG. 8D,method 1100 further comprises (block 1116) positioning, before (block1118) injecting feedstock material 750 into mold cavity 808, ejector pin850 in a recessed position, such that during (block 1118) injectingfeedstock material 750 into mold cavity 808, tapered lower surface 854of pin head 852 of ejector pin 850 is in direct sealing contact withtapered portion 864 of pin chamber 862 in which ejector pin 850 isseated. The preceding subject matter of this paragraph characterizesexample 76 of the present disclosure, wherein example 76 also includesthe subject matter according to example 75, above.

Tapered lower surface 854 of pin head 852 being in direct sealingcontact with tapered portion 864 of pin chamber 862 facilitates creatinga positive seal between pin head 852 and mold cavity wall 866 duringinjection of feedstock material 750. More specifically, with ejector pin850 in the recessed position, positive pressure inside mold cavity 808reacts against pin head 852 and tends to force ejector pin 850 deeperinto pin chamber 862, such that the greater the pressure inside moldcavity 808, the better the seal created between tapered lower surface854 and tapered portion 864 of pin chamber 862. Accordingly, taperedportion 864 of pin chamber 862 tends to reduce or eliminate a potentialfor ejector pin 850 to become adhered in the recessed position, and thusinoperable to eject monolithic precursor test coupon 100, due to binder749 seeping between pin head 852 and mold cavity wall 866.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS.2A-2C and 7, feedstock material 750 further comprises binder 749, and,according to method 1100, (block 1118) injecting feedstock material 750into mold cavity 808 comprises (block 1128) forming monolithic precursortest coupon 100 in a green state. Method 1100 further comprises (block1138) de-binding monolithic precursor test coupon 100 from the greenstate to a brown state. The preceding subject matter of this paragraphcharacterizes example 77 of the present disclosure, wherein example 77also includes the subject matter according to any one of examples 65 to76, above.

De-binding monolithic precursor test coupon 100 from the green state tothe brown state facilitates eventual production of test coupon 900(shown in FIG. 9) having desired material properties. For example,monolithic precursor test coupon 100 is subjected to a suitable thermalor solvent-based process to remove binder 749.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS.2A-2C and 9, according to method 1100, (block 1142) removing runners 130is performed before (block 1138) de-binding monolithic precursor testcoupon 100 from the green state to the brown state. The precedingsubject matter of this paragraph characterizes example 78 of the presentdisclosure, wherein example 78 also includes the subject matteraccording to example 77, above.

Removing runners 130 before de-binding simplifies removal of runners 130from monolithic precursor test coupon 100 due to a lack of structuralstrength of monolithic precursor test coupon 100 in the green state ascompared to the finished material state.

Referring to FIGS. 11A-11C and particularly to, e.g., FIGS. 2A-2C and 9,according to method 1100, (block 1142) removing runners 130 is performedafter (block 1138) de-binding monolithic precursor test coupon 100 fromthe green state to the brown state. The preceding subject matter of thisparagraph characterizes example 79 of the present disclosure, whereinexample 79 also includes the subject matter according to example 77,above.

Removing runners 130 after de-binding facilitates maintaining astructural integrity of monolithic precursor test coupon 100 during thede-binding process. More specifically, runners 130 interconnecting firstgrip portion 110 and second grip portion 112 increase a structuralstability of first grip portion 110, second grip portion 112, andintermediate portion 114, thereby inhibiting breakage or warping offirst grip portion 110, second grip portion 112, and intermediateportion 114 during and after de-binding.

Referring to FIGS. 11A-11C and particularly to, e.g., FIGS. 2A-2C and 9,method 1100 further comprises (block 1140) sintering monolithicprecursor test coupon 100 from the brown state to a finished materialstate. The preceding subject matter of this paragraph characterizesexample 80 of the present disclosure, wherein example 80 also includesthe subject matter according to any one of examples 77 to 79, above.

Sintering monolithic precursor test coupon 100 from the brown state tothe finished material state facilitates production of test coupon 900(shown in FIG. 9) having desired material properties. For example,monolithic precursor test coupon 100 is subjected to a temperaturegreater than 1100 degrees Celsius (2012 degrees Fahrenheit) in asuitable vacuum or other non-oxidizing atmosphere. In the finishedmaterial state, metal powder 748 originally included in feedstockmaterial 750 and retained in substance 150 has been transformed intopost-sintered metal 950.

Referring to FIGS. 11A-11C and particularly to, e.g., FIGS. 2A-2C and 9,according to method 1100, (block 1142) removing runners 130 is performedbefore (block 1140) sintering monolithic precursor test coupon 100 fromthe brown state to the finished material state. The preceding subjectmatter of this paragraph characterizes example 81 of the presentdisclosure, wherein example 81 also includes the subject matteraccording to example 80, above.

Removing runners 130 before sintering simplifies removal of runners 130from monolithic precursor test coupon 100 due to a lack of structuralstrength of monolithic precursor test coupon 100 in the brown state ascompared to the finished material state.

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS.2A-2C and 9, according to method 1100, (block 1142) removing runners 130is performed after (block 1140) sintering monolithic precursor testcoupon 100 from the brown state to the finished material state. Thepreceding subject matter of this paragraph characterizes example 82 ofthe present disclosure, wherein example 82 also includes the subjectmatter according to example 80, above.

Removing runners 130 after sintering facilitates maintaining astructural integrity of monolithic precursor test coupon 100 during thesintering process. More specifically, runners 130 interconnecting firstgrip portion 110 and second grip portion 112 increase a structuralstability of first grip portion 110, second grip portion 112, andintermediate portion 114, thereby inhibiting breakage or warping offirst grip portion 110, second grip portion 112, and intermediateportion 114 during and after sintering (e.g., during a cool-down processafter sintering).

Referring generally to FIGS. 11A-11C and particularly to, e.g., FIGS. 7,8A, 8B, 8E, and 8F, first-grip-portion cavity 810, intermediate-portioncavity 814, and second-grip-portion cavity 812 are arranged in seriesalong longitudinal mold-cavity axis 806. Intermediate-portion cavity 814comprises gauge-portion cavity 820, which defines a gaugecross-sectional flow area, perpendicular to longitudinal mold-cavityaxis 806. The gauge cross-sectional flow area is a least value of a setof cross-sectional flow areas, perpendicular to longitudinal mold-cavityaxis 806 at all locations along first-grip-portion cavity 810,intermediate-portion cavity 814, and second-grip-portion cavity 812.According to method 1100, (block 1118) injecting feedstock material 750into mold cavity 808 comprises (block 1124) flowing feedstock material750 simultaneously through a first flow path, from first-grip-portioncavity 810, through intermediate-portion cavity 814, and intosecond-grip-portion cavity 812, and through second flow paths, arrangedin parallel to the first flow path and each other, fromfirst-grip-portion cavity 810, through runner cavities 830, and intosecond-grip-portion cavity 812. The preceding subject matter of thisparagraph characterizes example 83 of the present disclosure, whereinexample 83 also includes the subject matter according to any one ofexamples 65 to 82, above.

Runner cavities 830 enable a portion of feedstock material 750 to bypassa flow restriction, caused by the gauge cross-sectional flow area beingthe least value of the set of cross-sectional flow areas, perpendicularto longitudinal mold-cavity axis 806. More specifically, the pluralityof second flow paths in parallel to the first flow path throughgauge-portion cavity 820 and each other provide back-fill of downstreamportions of monolithic precursor test coupon 100 (shown in FIG. 1A). Thebypass flow area provided by runner cavities 830 thus enables formationof monolithic precursor test coupon 100 having a proper distribution andintegrity of feedstock material 750 at an injection rate that avoidsproblems of binder shearing or premature binder cross-linking.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10A-10E, method 1200 of removing flash 180 from gauge portion 120 ofmonolithic precursor test coupon 100 using flash-removal tool 1000 isdisclosed. Flash-removal tool 1000 comprises tool body 1002, extendingalong longitudinal tool axis 1004. Flash-removal tool 1000 alsocomprises tooth 1010 and engagement surface 1020, spaced apart fromtooth 1010 along longitudinal tool axis 1004. Tooth 1010 projects fromtool body 1002 in first direction 1090 and comprises shearing surface1014, facing in first direction 1090 and located offset distance 1012away from longitudinal tool axis 1004 in second direction 1092. Firstdirection 1090 and second direction 1092 are orthogonal to each otherand define a plane, perpendicular to longitudinal tool axis 1004. Method1200 comprises (block 1210) coupling engagement surface 1020 offlash-removal tool 1000 against first precursor-coupon end 102 ofmonolithic precursor test coupon 100. Method 1200 also comprises (block1214) orienting longitudinal tool axis 1004 parallel to longitudinalsymmetry axis 106 of monolithic precursor test coupon 100. Shearingsurface 1014 registers longitudinally with flash 180. Method 1200further comprises (block 1236) shearing, using shearing surface 1014,flash 180 from gauge portion 120. The preceding subject matter of thisparagraph characterizes example 84 of the present disclosure.

Tooth 1010 projecting from tool body 1002 in first direction 1090 andhaving shearing surface 1014, located offset distance 1012 away fromlongitudinal tool axis 1004 in second direction 1092, such that shearingsurface 1014 registers longitudinally with flash 180 when engagementsurface 1020 of flash-removal tool 1000 couples against firstprecursor-coupon end 102 and longitudinal tool axis 1004 is orientedparallel to longitudinal symmetry axis 106 of monolithic precursor testcoupon 100, facilitates removal of flash 180 from gauge portion 120 atan increased speed, without requiring complex alignment procedures oradjustments. For example, as shown in FIG. 10E, gauge portion 120 has acircular cross-section and a radius 118, and offset distance 1012 equalsradius 118 plus tolerance 1016.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10E, according to method 1200, (block 1214) orienting longitudinal toolaxis 1004 parallel to longitudinal symmetry axis 106 of monolithicprecursor test coupon 100 comprises (block 1216) positioning shearingsurface 1014 at radial distance 119 from longitudinal symmetry axis 106.Flash 180 projects radially from surface 116 of gauge portion 120through radial distance 119. The preceding subject matter of thisparagraph characterizes example 85 of the present disclosure, whereinexample 85 also includes the subject matter according to example 84,above.

Positioning shearing surface 1014 at radial distance 119 fromlongitudinal symmetry axis 106 enables shearing surface 1014 to registerwith flash 180 projecting from surface 116, without requiring complexalignment procedures or adjustments beyond coupling engagement surface1020 to monolithic precursor test coupon 100 and orienting longitudinaltool axis 1004 parallel to longitudinal symmetry axis 106 of monolithicprecursor test coupon 100.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10Cand 10D, monolithic precursor test coupon 100 further comprises firstgrip portion 110, second grip portion 112, and intermediate portion 114,interconnecting first grip portion 110 and second grip portion 112.Monolithic precursor test coupon 100 also comprises runners 130,directly interconnecting first grip portion 110 and second grip portion112 and not directly connected to intermediate portion 114. Intermediateportion 114 of monolithic precursor test coupon 100 comprises gaugeportion 120. The preceding subject matter of this paragraphcharacterizes example 86 of the present disclosure, wherein example 86also includes the subject matter according to example 84 or 85, above.

Coupling engagement surface 1020 to monolithic precursor test coupon 100and orienting longitudinal tool axis 1004 parallel to longitudinalsymmetry axis 106 of monolithic precursor test coupon 100 enables tooth1010 to slide between runners 130 of monolithic precursor test coupon100 such that shearing surface 1014 aligns precisely with flash 180 ongauge portion 120.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, method 1200 further comprises (block 1209) inserting toolbody 1002 between two of runners 130. The preceding subject matter ofthis paragraph characterizes example 87 of the present disclosure,wherein example 87 also includes the subject matter according to example86, above.

Inserting tool body 1002 between two of runners 130 enables tooth 1010to slide between runners 130 of monolithic precursor test coupon 100such that shearing surface 1014 aligns precisely with flash 180 on gaugeportion 120.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10D and 10E, according to method 1200, (block 1214) orientinglongitudinal tool axis 1004 parallel to longitudinal symmetry axis 106of monolithic precursor test coupon 100 comprises (block 1218)circumferentially spacing shearing surface 1014 away from flash 180, and(block 1236) shearing flash 180 comprises (block 1238) rotating toolbody 1002 about longitudinal symmetry axis 106 such that shearingsurface 1014 moves circumferentially toward, and contacts, flash 180.The preceding subject matter of this paragraph characterizes example 88of the present disclosure, wherein example 88 also includes the subjectmatter according to example 86 or 87, above.

Circumferentially spacing shearing surface 1014 away from flash 180 (asshown in position 1001 in FIG. 10E), and then rotating tool body 1002about longitudinal symmetry axis 106 (as indicated by the large curvedarrow in FIG. 10D) such that shearing surface 1014 movescircumferentially toward, and contacts, flash 180 (as shown in position1003 in FIG. 10E), enables flash-removal tool 1000 to be insertedbetween a pair of runners 130 and used to remove flash 180 withoutinterference between tool body 1002 and runners 130.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10D and 10E, flash 180 has portions each radially aligned with arespective one of runners 130, and, according to method 1200, (block1238) rotating tool body 1002 comprises (block 1240) shearing one of theportions of flash 180 before tool body 1002 contacts the respective oneof runners 130. The preceding subject matter of this paragraphcharacterizes example 89 of the present disclosure, wherein example 89also includes the subject matter according to example 88, above.

Rotating tool body 1002 to shear one of the portions of flash 180 beforetool body 1002 contacts the respective one of runners 130 enablesflash-removal tool 1000 to be used to remove flash 180 radially alignedwith runners 130. For example, mold 800 includes runner cavities 830defined between respective pairs of mold sections 860 (shown in FIGS.8A, 8B, 8E, and 8F), which reduces or eliminates interference of runners130, formed in runner cavities 830, with mold sections 860 duringdisassembly of mold sections 860. This placement of runner cavities 830causes portions of flash 180, formed by seepage of feedstock material750 between parting surfaces 870 of mold sections 860, to be formed inradial alignment with each runner 130, with respect to radial direction132. Radial direction 132 is defined with respect to a cross section ofintermediate portion 114 taken along longitudinal symmetry axis 106, asshown in FIG. 10E. For example, tooth 1010 projecting from tool body1002 in first direction 1090, and having shearing surface 1014, locatedoffset distance 1012 away from longitudinal tool axis 1004 in seconddirection 1092, enables tooth 1010 to slide between runners 130 suchthat, when tool body 1002 is inserted between runners 130, shearingsurface 1014 is contactable against flash 180 under one of runners 130.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, flash-removal tool 1000 further comprises positioninggroove 1006 defined in tool body 1002, positioning groove 1006 extendinglongitudinally between engagement surface 1020 and tooth 1010. Accordingto method 1200, (block 1214) orienting longitudinal tool axis 1004parallel to longitudinal symmetry axis 106 of monolithic precursor testcoupon 100 comprises (block 1222) receiving a portion of monolithicprecursor test coupon 100 in positioning groove 1006. The precedingsubject matter of this paragraph characterizes example 90 of the presentdisclosure, wherein example 90 also includes the subject matteraccording to any one of examples 84 to 89, above.

Receiving a portion of monolithic precursor test coupon 100 inpositioning groove 1006 facilitates stable positioning of flash-removaltool 1000 against monolithic precursor test coupon 100.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, according to method 1200, (block 1210) coupling engagementsurface 1020 of flash-removal tool 1000 against first precursor-couponend 102 comprises (block 1212) coupling longitudinal end-wall 1034 ofpositioning groove 1006 against first precursor-coupon end 102 ofmonolithic precursor test coupon 100. The preceding subject matter ofthis paragraph characterizes example 91 of the present disclosure,wherein example 91 also includes the subject matter according to example90, above.

Coupling engagement surface 1020 against first precursor-coupon end 102by coupling longitudinal end-wall 1034 of positioning groove 1006against first precursor-coupon end 102 combines the step forlongitudinally positioning tooth 1010 with an additional step for stablepositioning of flash-removal tool 1000 against monolithic precursor testcoupon 100, facilitating faster performance of method 1200.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, monolithic precursor test coupon 100 further comprisesfirst grip portion 110, second grip portion 112, and intermediateportion 114, interconnecting first grip portion 110 and second gripportion 112. Intermediate portion 114 comprises gauge portion 120, andpositioning groove 1006 comprises cylindrically contoured portion 1030,extending parallel to longitudinal tool axis 1004. According to method1200, (block 1222) receiving the portion of monolithic precursor testcoupon 100 in positioning groove 1006 comprises (block 1224) couplingcylindrically contoured portion 1030 of positioning groove 1006 againstfirst grip portion 110. The preceding subject matter of this paragraphcharacterizes example 92 of the present disclosure, wherein example 92also includes the subject matter according to example 90 or 91, above.

Coupling cylindrically contoured portion 1030 of positioning groove 1006against first grip portion 110 facilitates stable positioning offlash-removal tool 1000 against monolithic precursor test coupon 100 forimplementations in which first grip portion 110 has a cylindricalprofile complementary to cylindrically contoured portion 1030.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, positioning groove 1006 further comprises tapered portion1032, parallel to longitudinal tool axis 1004 and extendinglongitudinally between cylindrically contoured portion 1030 and tooth1010. According to method 1200, (block 1222) receiving the portion ofmonolithic precursor test coupon 100 in positioning groove 1006 furthercomprises (block 1226) coupling tapered portion 1032 of positioninggroove 1006 against intermediate portion 114. The preceding subjectmatter of this paragraph characterizes example 93 of the presentdisclosure, wherein example 93 also includes the subject matteraccording to example 92, above.

Coupling tapered portion 1032 of positioning groove 1006 againstintermediate portion 114 facilitates stable positioning of flash-removaltool 1000 against monolithic precursor test coupon 100 forimplementations in which intermediate portion 114, adjacent to firstgrip portion 110, has a longitudinally tapering profile complementary totapered portion 1032 .

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, flash-removal tool 1000 further comprises secondary groove1035, defined in tool body 1002. Tooth 1010 divides tool body 1002longitudinally into two sides. Positioning groove 1006 extendslongitudinally on one of the two sides, and secondary groove 1035extends longitudinally on another of the two sides and faces in firstdirection 1090. According to method 1200, (block 1214) orientinglongitudinal tool axis 1004 parallel to longitudinal symmetry axis 106of monolithic precursor test coupon 100 further comprises (block 1230)receiving an additional portion of monolithic precursor test coupon 100in secondary groove 1035. The preceding subject matter of this paragraphcharacterizes example 94 of the present disclosure, wherein example 94also includes the subject matter according to any one of examples 90 to93, above.

Receiving another portion of monolithic precursor test coupon 100 insecondary groove 1035 further facilitates stable positioning offlash-removal tool 1000 against monolithic precursor test coupon 100.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, monolithic precursor test coupon 100 further comprisesfirst grip portion 110, second grip portion 112, and intermediateportion 114, interconnecting first grip portion 110 and second gripportion 112. Secondary groove 1035 comprises cylindrically contouredsecondary portion 1036, extending parallel to longitudinal tool axis1004. According to method 1200, (block 1230) receiving the additionalportion of monolithic precursor test coupon 100 in secondary groove 1035comprises (block 1232) coupling cylindrically contoured secondaryportion 1036 of secondary groove 1035 against second grip portion 112.The preceding subject matter of this paragraph characterizes example 95of the present disclosure, wherein example 95 also includes the subjectmatter according to example 94, above.

Coupling cylindrically contoured secondary portion 1036 of secondarygroove 1035 against second grip portion 112 further facilitates stablepositioning of flash-removal tool 1000 against monolithic precursor testcoupon 100 for implementations in which second grip portion 112 has acylindrical profile complementary to cylindrically contoured secondaryportion 1036.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, secondary groove 1035 further comprises tapered secondaryportion 1038, parallel to longitudinal tool axis 1004 and extendinglongitudinally between cylindrically contoured secondary portion 1036and tooth 1010. According to method 1200, (block 1230) receiving theadditional portion of monolithic precursor test coupon 100 in secondarygroove 1035 further comprises (block 1234) coupling tapered secondaryportion 1038 of secondary groove 1035 against intermediate portion 114.The preceding subject matter of this paragraph characterizes example 96of the present disclosure, wherein example 96 also includes the subjectmatter according to example 95, above.

Coupling tapered secondary portion 1038 of secondary groove 1035 againstintermediate portion 114 further facilitates stable positioning offlash-removal tool 1000 against monolithic precursor test coupon 100 forimplementations in which intermediate portion 114, adjacent to secondgrip portion 112, has a longitudinally tapering profile complementary totapered secondary portion 1038.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10E, according to method 1200, (block 1222) receiving the portion ofmonolithic precursor test coupon 100 in positioning groove 1006comprises (block 1228) maintaining gap 1018 between tool body 1002 offlash-removal tool 1000 and gauge portion 120. The preceding subjectmatter of this paragraph characterizes example 97 of the presentdisclosure, wherein example 97 also includes the subject matteraccording to any one of examples 90 to 96, above.

Maintaining gap 1018 between tool body 1002 of flash-removal tool 1000and gauge portion 120 facilitates reducing or eliminating damage ormarring, during removal of flash 180, to gauge portion 120 of monolithicprecursor test coupon 100. Integrity of gauge portion 120 is necessaryto enable accurate determination of material properties from testing oftest coupon 900 (shown in FIG. 9) subsequently formed from monolithicprecursor test coupon 100. For example, a depth of positioning groove1006 and, in some examples, a depth of secondary groove 1035, isselected to create gap 1018 when first grip portion 110 is received inpositioning groove 1006 and second grip portion 112 is received insecondary groove 1035.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C and 10D, engagement surface 1020 is located preselected distance1022 away from tooth 1010 along longitudinal tool axis 1004. Accordingto method 1200, (block 1214) orienting longitudinal tool axis 1004parallel to longitudinal symmetry axis 106 of monolithic precursor testcoupon 100 comprises (block 1220) aligning shearing surface 1014longitudinally with gauge portion 120. The preceding subject matter ofthis paragraph characterizes example 98 of the present disclosure,wherein example 98 also includes the subject matter according to any oneof examples 84 to 97, above.

Engagement surface 1020 being located preselected distance 1022 awayfrom tooth 1010 along longitudinal axis 1004 enables shearing surface1014 to align longitudinally with gauge portion 120 when engagementsurface 1020 engages monolithic precursor test coupon 100 andlongitudinal tool axis 1004 is aligned with longitudinal symmetry axis106.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10A and 10C, method 1200 further comprises (block 1202) adjustingpreselected distance 1022 before (block 1214) orienting longitudinaltool axis 1004 parallel to longitudinal symmetry axis 106 of monolithicprecursor test coupon 100. The preceding subject matter of thisparagraph characterizes example 99 of the present disclosure, whereinexample 99 also includes the subject matter according to example 98,above.

Adjusting preselected distance 1022 prior to use on monolithic precursortest coupon 100 facilitates an adaptability of flash-removal tool 1000to monolithic precursor test coupon 100 having various sizes. Forexample, monolithic precursor test coupon 100 is manufactured indifferent longitudinal sizes corresponding to different sizes of testcoupon 900 needed for use with different material property testingmachines (not shown). Preselected distance 1022 being adjustable enablesa single tool, such as flash-removal tool 1000, to be used with morethan one size of monolithic precursor test coupon 100.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10A, flash-removal tool 1000 comprises telescoping portion 1040, coupledto tool body 1002, and engagement surface 1020 is defined on telescopingportion 1040. According to method 1200, (block 1202) adjustingpreselected distance 1022 comprises (block 1204) re-positioningtelescoping portion 1040 along longitudinal tool axis 1004 with respectto tool body 1002. The preceding subject matter of this paragraphcharacterizes example 100 of the present disclosure, wherein example 100also includes the subject matter according to example 99, above.

Re-positioning of telescoping portion 1040 with respect to tool body1002 provides a mechanically simple implementation for adjustingpreselected distance 1022.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10A, according to method 1200, (block 1202) adjusting preselecteddistance 1022 further comprises (block 1206) selectively lockingtelescoping portion 1040 in position relative to tool body 1002 after(block 1204) re-positioning telescoping portion 1040 along longitudinaltool axis 1004 with respect to tool body 1002. The preceding subjectmatter of this paragraph characterizes example 101 of the presentdisclosure, wherein example 101 also includes the subject matteraccording to example 100, above.

Selectively locking telescoping portion 1040 facilitates a stability andease of use of flash-removal tool 1000 after adjusting preselecteddistance 1022.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10A, detent 1044 is located on one of telescoping portion 1040 or toolbody 1002, and plurality of catches 1046 is arranged longitudinally onanother of telescoping portion 1040 or tool body 1002. According tomethod 1200, (block 1206) selectively locking telescoping portion 1040in position relative to tool body 1002 comprises (block 1208) movingdetent 1044 into interference with one of plurality of catches 1046. Thepreceding subject matter of this paragraph characterizes example 102 ofthe present disclosure, wherein example 102 also includes the subjectmatter according to example 101, above.

Moving detent 1044 into interference with one of catches 1046corresponding to preselected distance 1022 provides a mechanicallysimple and effective implementation of locking telescoping portion 1040.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10B AND 10E, monolithic precursor test coupon 100 further comprisesfirst grip portion 110, second grip portion 112, intermediate portion114, interconnecting first grip portion 110 and second grip portion 112.Monolithic precursor test coupon 100 also comprises runners 130,directly interconnecting first grip portion 110 and second grip portion112 and not directly connected to intermediate portion 114. Intermediateportion 114 comprises gauge portion 120, and flash 180 has portions eachradially aligned with a respective one of runners 130. Flash-removaltool 1000 further comprises second tooth 1011. Longitudinal tool axis1004 is located between tooth 1010 and second tooth 1011. According tomethod 1200, (block 1236) shearing flash 180 from gauge portion 120comprises (block 1242) shearing a first one of the portions of flash 180with tooth 1010 and a second one of the portions of flash 180 withsecond tooth 1011. The preceding subject matter of this paragraphcharacterizes example 103 of the present disclosure, wherein example 103also includes the subject matter according to any one of examples 84 to102, above.

Shearing a first one of the portions of flash 180 with tooth 1010 and asecond one of the portions of flash 180 with second tooth 1011facilitates removal of multiple portions of flash 180 without requiringdisengagement of flash-removal tool 1000 from monolithic precursor testcoupon 100 and subsequent re-positioning of flash-removal tool 1000 tore-position tooth 1010 adjacent to the second portion of flash 180,facilitating increased speed of removal of flash 180 from monolithicprecursor test coupon 100.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10E, according to method 1200, (block 1236) shearing flash 180 fromgauge portion 120 comprises (block 1244) shearing flash 180 frommonolithic precursor test coupon 100 that is in a green state. Thepreceding subject matter of this paragraph characterizes example 104 ofthe present disclosure, wherein example 104 also includes the subjectmatter according to any one of examples 84 to 103, above.

Shearing flash 180 from monolithic precursor test coupon 100 in thegreen state simplifies removal of flash 180 from monolithic precursortest coupon 100 due to a lack of structural strength of monolithicprecursor test coupon 100 in the green state as compared to the finishedmaterial state. Monolithic precursor test coupon 100 remains in thegreen state until subjected to a de-binding process, which results in atransformation to a brown state.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10E, according to method 1200, (block 1236) shearing flash 180 fromgauge portion 120 comprises (block 1246) shearing flash 180 frommonolithic precursor test coupon 100 that is in a brown state. Thepreceding subject matter of this paragraph characterizes example 105 ofthe present disclosure, wherein example 105 also includes the subjectmatter according to any one of examples 84 to 103, above.

Shearing flash 180 from monolithic precursor test coupon 100 in thebrown state simplifies removal of flash 180 from monolithic precursortest coupon 100 due to a lack of structural strength of monolithicprecursor test coupon 100 in the brown state as compared to the finishedmaterial state. After de-binding, monolithic precursor test coupon 100remains in the brown state until subjected to a sintering process, whichresults in a transformation to a finished material state.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10E, according to method 1200, (block 1236) shearing flash 180 fromgauge portion 120 comprises (block 1248) shearing flash 180 frommonolithic precursor test coupon 100 that is in a finished materialstate. The preceding subject matter of this paragraph characterizesexample 106 of the present disclosure, wherein example 106 also includesthe subject matter according to any one of examples 84 to 103, above.

Shearing flash 180 from monolithic precursor test coupon 100 in thefinished material state facilitates reducing or eliminating a risk ofdamage to gauge portion 120 during removal of flash 180, due toincreased structural strength of monolithic precursor test coupon 100 inthe finished material state.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIG.10E, monolithic precursor test coupon 100 further comprises first gripportion 110, second grip portion 112, and intermediate portion 114,interconnecting first grip portion 110 and second grip portion 112.Monolithic precursor test coupon 100 also comprises runners 130,directly interconnecting first grip portion 110 and second grip portion112 and not directly connected to intermediate portion 114. Intermediateportion 114 comprises gauge portion 120, and flash 180 has portions eachradially aligned with a respective one of runners 130. According tomethod 1200, (block 1236) shearing flash 180 from gauge portion 120comprises (block 1250) shearing a first one of the portions of flash180. The preceding subject matter of this paragraph characterizesexample 107 of the present disclosure, wherein example 107 also includesthe subject matter according to any one of examples 84 to 106, above.

Shearing a first portion of flash 180 that is radially aligned with oneof runners 130 facilitates maintaining runners 130 intact during flashremoval, which in turn increases a structural stability of monolithicprecursor test coupon 100 during flash removal, particularly forexamples in which monolithic precursor test coupon 100 is in a greenstate or a brown state during flash removal.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS.10C-10E, method 1200 further comprises, after (block 1250) shearing thefirst one of the portions of flash 180, (block 1254) removingflash-removal tool 1000 from between a first adjacent pair of runners130, (block 1256) re-positioning flash-removal tool 1000 between asecond adjacent pair of runners 130, and (block 1258) shearing, byshearing surface 1014, a second one of the portions of flash 180 fromgauge portion 120. The preceding subject matter of this paragraphcharacterizes example 108 of the present disclosure, wherein example 108also includes the subject matter according to example 107, above.

Re-positioning flash-removal tool 1000 between a second adjacent pair ofrunners 130 and shearing a second portion of the flash that is radiallyaligned with another of runners 130 facilitates maintaining runners 130intact during flash removal using flash-removal tool 1000 having asingle tooth 1010, which simplifies manufacture and maintenance offlash-removal tool 1000.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS. 9and 10E, monolithic precursor test coupon 100 further comprises firstgrip portion 110, second grip portion 112, and intermediate portion 114,interconnecting first grip portion 110 and second grip portion 112.Monolithic precursor test coupon 100 also comprises runners 130,directly interconnecting first grip portion 110 and second grip portion112 and not directly connected to intermediate portion 114. Intermediateportion 114 of monolithic precursor test coupon 100 comprises gaugeportion 120. Method 1200 further comprises (block 1252) removing runners130 from monolithic precursor test coupon 100. According to method 1200,(block 1236) shearing flash 180 from gauge portion 120 is performedbefore (block 1252) removing runners 130 from monolithic precursor testcoupon 100. The preceding subject matter of this paragraph characterizesexample 109 of the present disclosure, wherein example 109 also includesthe subject matter according to any one of examples 84 to 108, above.

Shearing flash 180 before removal of runners 130 increases a structuralstability of monolithic precursor test coupon 100 during flash removal,particularly for examples in which monolithic precursor test coupon 100is in a green state or a brown state during flash removal.

Referring generally to FIGS. 12A-12D and particularly to, e.g., FIGS. 9and 10E, monolithic precursor test coupon 100 further comprises firstgrip portion 110, second grip portion 112, and intermediate portion 114,interconnecting first grip portion 110 and second grip portion 112.Monolithic precursor test coupon 100 also comprises runners 130,directly interconnecting first grip portion 110 and second grip portion112 and not directly connected to intermediate portion 114. Intermediateportion 114 of monolithic precursor test coupon 100 comprises gaugeportion 120. Method 1200 further comprises (block 1252) removing runners130 from monolithic precursor test coupon 100. According to method 1200,(block 1236) shearing flash 180 from gauge portion 120 is performedafter (block 1252) removing runners 130 from monolithic precursor testcoupon 100. The preceding subject matter of this paragraph characterizesexample 110 of the present disclosure, wherein example 110 also includesthe subject matter according to any one of examples 84 to 108, above.

Shearing flash 180 after removal of runners 130 facilitates reducing oreliminating interference of runners 130 with flash-removal tool 1000,while maintaining ease of alignment, provided by flash-removal tool1000.

Examples of the present disclosure may be described in the context ofaircraft manufacturing and service method 1300 as shown in FIG. 13 andaircraft 1302 as shown in FIG. 14. During pre-production, illustrativemethod 1300 may include specification and design (block 1304) ofaircraft 1302 and material procurement (block 1306). During production,component and subassembly manufacturing (block 1308) and systemintegration (block 1310) of aircraft 1302 may take place. Thereafter,aircraft 1302 may go through certification and delivery (block 1312) tobe placed in service (block 1314). While in service, aircraft 1302 maybe scheduled for routine maintenance and service (block 1316). Routinemaintenance and service may include modification, reconfiguration,refurbishment, etc. of one or more systems of aircraft 1302.

Each of the processes of illustrative method 1300 may be performed orcarried out by a system integrator, a third party, and/or an operator(e.g., a customer). For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG.14, aircraft 1302 produced by illustrative method 1300may include airframe 1318 with a plurality of high-level systems 1320and interior 1322. Examples of high-level systems 1320 include one ormore of propulsion system 1324, electrical system 1326, hydraulic system1328, and environmental system 1330. Any number of other systems may beincluded. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive industry. Accordingly, in addition to aircraft 1302, theprinciples disclosed herein may apply to other vehicles, e.g., landvehicles, marine vehicles, space vehicles, etc.

Apparatus(es) and method(s) shown or described herein may be employedduring any one or more of the stages of the manufacturing and servicemethod 1300. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing (block 1308) may be fabricatedor manufactured in a manner similar to components or subassembliesproduced while aircraft 1302 is in service (block 1314). Also, one ormore examples of the apparatus(es), method(s), or combination thereofmay be utilized during production stages 1308 and 1310, for example, bysubstantially expediting assembly of or reducing the cost of aircraft1302. Similarly, one or more examples of the apparatus or methodrealizations, or a combination thereof, may be utilized, for example andwithout limitation, while aircraft 1302 is in service (block 1314)and/or during maintenance and service (block 1316).

Different examples of the apparatus(es) and method(s) disclosed hereininclude a variety of components, features, and functionalities. Itshould be understood that the various examples of the apparatus(es) andmethod(s) disclosed herein may include any of the components, features,and functionalities of any of the other examples of the apparatus(es)and method(s) disclosed herein in any combination, and all of suchpossibilities are intended to be within the scope of the presentdisclosure.

Many modifications of examples set forth herein will come to mind to oneskilled in the art to which the present disclosure pertains having thebenefit of the teachings presented in the foregoing descriptions and theassociated drawings.

Therefore, it is to be understood that the present disclosure is not tobe limited to the specific examples illustrated and that modificationsand other examples are intended to be included within the scope of theappended claims. Moreover, although the foregoing description and theassociated drawings describe examples of the present disclosure in thecontext of certain illustrative combinations of elements and/orfunctions, it should be appreciated that different combinations ofelements and/or functions may be provided by alternative implementationswithout departing from the scope of the appended claims. Accordingly,parenthetical reference numerals in the appended claims are presentedfor illustrative purposes only and are not intended to limit the scopeof the claimed subject matter to the specific examples provided in thepresent disclosure.

1-44. (canceled)
 45. A flash-removal tool (1000) comprising: a tool body (1002), extending along a longitudinal tool axis (1004); a tooth (1010), projecting from the tool body (1002) in a first direction (1090); and an engagement surface (1020), perpendicular to the longitudinal tool axis (1004) and located a preselected distance (1022) away from the tooth (1010) along the longitudinal tool axis (1004); and wherein: the tooth (1010) comprises a shearing surface (1014), facing in the first direction (1090) and located an offset distance (1012) away from the longitudinal tool axis (1004) in a second direction (1092); and the first direction (1090) and the second direction (1092) are orthogonal to each other and define a plane, perpendicular to the longitudinal tool axis (1004).
 46. The flash-removal tool (1000) according to claim 45, wherein the engagement surface (1020) is defined on the tool body (1002), such that the preselected distance (1022) is non-adjustable.
 47. The flash-removal tool (1000) according to claim 45, further comprising an extendable portion (1041), movable with respect to the tool body (1002) to adjust the preselected distance (1022).
 48. The flash-removal tool (1000) according to claim 47, wherein: the extendable portion (1041) comprises a telescoping portion (1040), coupled to the tool body (1002); and the engagement surface (1020) is defined on the telescoping portion (1040).
 49. The flash-removal tool (1000) according to claim 48, further comprising a lock (1043), operable to selectively lock the telescoping portion (1040) in position relative to the tool body (1002) after the preselected distance (1022) is adjusted.
 50. The flash-removal tool (1000) according to claim 49, wherein the lock (1043) comprises: a detent (1044), located on one of the telescoping portion (1040) or the tool body (1002); and a plurality of catches (1046), arranged longitudinally on another of the telescoping portion (1040) or the tool body (1002), and wherein each one of the catches (1046) is configured to interfere with the detent (1044) when the telescoping portion (1040) is correspondingly adjusted relative to the tool body (1002).
 51. The flash-removal tool (1000) according to claim 45, further comprising a positioning groove (1006), defined in the tool body (1002), and wherein the positioning groove (1006) extends longitudinally between the engagement surface (1020) and the tooth (1010) and faces in the first direction (1090).
 52. The flash-removal tool (1000) according to claim 51, wherein the engagement surface (1020) forms a longitudinal end-wall (1034) of the positioning groove (1006).
 53. The flash-removal tool (1000) according to claim 51, wherein the positioning groove (1006) comprises a cylindrically contoured portion (1030), extending parallel to the longitudinal tool axis (1004).
 54. The flash-removal tool (1000) according to claim 53, wherein the positioning groove (1006) further comprises a tapered portion (1032), extending longitudinally between the cylindrically contoured portion (1030) and the tooth (1010) and parallel to the longitudinal tool axis (1004). 55-110. (canceled)
 111. The flash-removal tool (1000) according to claim 51, further comprising a secondary groove (1035), defined in the tool body (1002), wherein the tooth (1010) divides the tool body (1002) longitudinally into two sides, wherein the positioning groove (1006) extends longitudinally on one of the two sides, and wherein the secondary groove (1035) extends longitudinally on another of the two sides and faces in the first direction (1090).
 112. The flash-removal tool (1000) according to claim 111, wherein the secondary groove (1035) comprises a cylindrically contoured secondary portion (1036), extending parallel to the longitudinal tool axis (1004).
 113. The flash-removal tool (1000) according to claim 112, wherein the secondary groove (1035) further comprises a tapered secondary portion (1038), parallel to the longitudinal tool axis (1004) and extending longitudinally between the cylindrically contoured secondary portion (1036) and the tooth (1010).
 114. The flash-removal tool (1000) according to claim 45, further comprising a second tooth (1011), and wherein the longitudinal tool axis (1004) is located between the tooth (1010) and the second tooth (1011).
 115. The flash-removal tool (1000) according to claim 114, wherein the second tooth (1011) is located the preselected distance (1022) away from the engagement surface (1020) along the longitudinal tool axis (1004).
 116. The flash-removal tool (1000) according to claim 45, wherein the tooth (1010) is monolithic with the tool body (1002).
 117. The flash-removal tool (1000) according to claim 45, wherein the tooth (1010) is formed separately from, and coupled to, the tool body (1002).
 118. The flash-removal tool (1000) according to claim 45, wherein: the tool body (1002) extends along the longitudinal tool axis (1004) from a first end (1050) to a second end (1052); and the engagement surface (1020) is located adjacent to the first end (1050).
 119. The flash-removal tool (1000) according to claim 118, wherein the tooth (1010) is located at the second end (1052).
 120. The flash-removal tool (1000) according to claim 118, wherein the tooth (1010) is spaced apart from the second end (1052) along the longitudinal tool axis (1004). 